Shaped Nonwoven

ABSTRACT

A nonwoven fabric. The nonwoven fabric can include a first surface and a second surface and a visually discernible pattern of three-dimensional features on one of the first or second surface. Each of the three-dimensional features can define a microzone comprising a first region and a second region. The first and second regions can have a difference in values for an intensive property, wherein the intensive property is one or more of thickness, basis weight, or volumetric density, and wherein the first surface has a TS7 value different than a TS7 value of the second surface.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of, and claims priority under 35U.S.C. § 120 to, U.S. patent application Ser. No. 17/087,695, filed onNov. 3, 2020, which is a continuation of U.S. patent application Ser.No. 15/840,455, filed on Dec. 13, 2017, now granted U.S. Pat. No.10,888,471, issued on Jan. 12, 2021, which claims the benefit, under 35U.S.C. § 119(e), of U.S. Provisional Patent Application Ser. No.62/434,547, filed on Dec. 15, 2016, the entire disclosures of which arefully incorporated by reference herein.

TECHNICAL FIELD

This invention relates to shaped, three-dimensional nonwoven fabrics andarticles made with shaped, three-dimensional nonwoven fabrics.

BACKGROUND OF THE INVENTION

Nonwoven fabrics are useful for a wide variety of applications,including absorbent personal care products, garments, medicalapplications, and cleaning applications. Nonwoven personal care productsinclude infant care items such as diapers, child care items such astraining pants, feminine care items such as sanitary napkins, and adultcare items such as incontinence products, pads, and pants. Nonwovengarments include protective workwear and medical apparel such assurgical gowns. Other nonwoven medical applications include nonwovenwound dressings and surgical dressings. Cleaning applications fornonwovens include towels and wipes. Still other uses of nonwoven fabricsare well known. The foregoing list is not considered exhaustive.

Various properties of nonwoven fabrics determine the suitability ofnonwoven fabrics for different applications. Nonwoven fabrics may beengineered to have different combinations of properties to suitdifferent needs. Variable properties of nonwoven fabrics includeliquid-handling properties such as wettability, distribution, andabsorbency, strength properties such as tensile strength and tearstrength, softness properties, durability properties such as abrasionresistance, and aesthetic properties. The physical shape of a nonwovenfabric also affects the functionality and aesthetic properties of thenonwoven fabric. Nonwoven fabrics are initially made into sheets which,when laid on a flat surface, may have a substantially planar,featureless surface or may have an array of surface features such asaperture or projections, or both. Nonwoven fabrics with apertures orprojections are often referred to as three-dimensional shaped nonwovenfabrics. The present disclosure relates to three-dimensional shapednonwoven fabrics.

Despite prior advances in the art of nonwoven fabrics, there remains aneed for improved nonwoven fabrics having three-dimensional surfacefeatures.

Further, there remains a need for processes and equipment formanufacturing improved nonwoven fabrics having three-dimensional surfacefeatures.

Further, there remains a need for articles, including absorbentarticles, utilizing improved nonwoven fabrics having three-dimensionalsurface features.

Further, there remains a need for absorbent articles utilizing nonwovenfabrics having three-dimensional surface features and which can bepackaged in a compressed form while minimizing the loss of thethree-dimensional surface features when opened from the package.

Further, there remains a need for absorbent articles utilizing soft,spunbond nonwoven fabrics having three-dimensional surface features thathave reduced fuzzing properties when in use.

Further, there remains a need for improved nonwoven fabrics havingthree-dimensional surface features and physical integrity combined withsoftness as measured by a Tissue Softness Analyzer marketed by EmtecElectronic GmbH.

Additionally, there remains a need for packages of absorbent articlescomprising soft nonwoven materials that have a reduced in-bag stackheight compared to conventional absorbent article packages so thepackages are convenient for caregivers to handle and store and so thatmanufacturers enjoy low distribution costs without a loss of aestheticsclarity, absorbency, or softness of the as-made absorbent article.

SUMMARY OF THE INVENTION

A nonwoven fabric is disclosed. The nonwoven fabric can include a firstsurface and a second surface and a visually discernible pattern ofthree-dimensional features on one of the first or second surface. Eachof the three-dimensional features can define a microzone comprising afirst region and a second region. The first and second regions can havea difference in values for an intensive property, wherein the intensiveproperty is one or more of thickness, basis weight, or volumetricdensity, and wherein the first surface has a TS7 value of less thanabout 15 dB V2 rms.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a photograph of an example of the present disclosure.

FIG. 2 is a photograph of an example of the present disclosure.

FIG. 3 is a photograph of an example of the present disclosure.

FIG. 4 is a cross-section of a portion of a fabric of the presentdisclosure as indicated in FIG. 1 .

FIG. 5A is a schematic drawing illustrating the cross-section of afilament made with a primary component A and a secondary component B ina side-by-side arrangement.

FIG. 5B is a schematic drawing illustrating the cross-section of afilament made with a primary component A and a secondary component B inan eccentric sheath/core arrangement.

FIG. 5C is a schematic drawing illustrating the cross-section of afilament made with a primary component A and a secondary component B ina concentric sheath/core arrangement.

FIG. 6 is a perspective view photograph of a tri-lobal, bicomponentfiber.

FIG. 7 is a schematic representation of an apparatus for making a fabricof the present disclosure.

FIG. 8 is a detail of a portion of the apparatus for bonding a portionof a fabric of the present disclosure.

FIG. 9 is a further detail of a portion of the apparatus for bonding aportion of a fabric of the present disclosure.

FIG. 10 is a detail of a portion of the apparatus for optionaladditional bonding of a portion of a fabric of the present disclosure.

FIG. 11 is a photograph of an example of the present disclosure.

FIG. 12 is a photograph of a portion of a forming belt useful for thepresent disclosure.

FIG. 13 is a cross-sectional depiction of a portion of the forming beltshown in FIG. 12 .

FIG. 14 is an image of a portion of a mask utilized to make the formingbelt shown in FIG. 12 .

FIG. 15 is an image of a portion of a mask utilized to make the formingbelt shown in FIG. 16 .

FIG. 16 is a photograph of a portion of a forming belt useful for thepresent disclosure.

FIG. 17 is an image of a portion of a mask utilized to make the formingbelt shown in FIG. 18 .

FIG. 18 is a photograph of a portion of a forming belt useful for thepresent disclosure.

FIG. 19 is a photograph of a portion of a forming belt useful for thepresent disclosure.

FIG. 20 an image of a mask utilized to make the forming belt shown inFIG. 19 .

FIG. 21 is a photograph of a fabric of the present disclosure made onthe forming belt shown in FIG. 19 .

FIG. 22 is a perspective schematic view of a forming belt of the presentdisclosure.

FIG. 23 is a plan view of a nonwoven substrate including nonwovenfabrics of the present disclosure.

FIG. 24 is a plan view of a nonwoven substrate including nonwovenfabrics of the present disclosure.

FIG. 25A is a plan view of a fabric of the present disclosure withportions removed for measurement of local basis weight.

FIG. 25B is a plan view of a fabric of the present disclosure withportions removed for measurement of local basis weight.

FIG. 26 is a graphical representation of cross-directional variation inbasis weight in a fabric of the present disclosure.

FIG. 27 is a schematic view of a package of the present disclosure.

FIG. 28 is a plan view of an absorbent article of the presentdisclosure.

FIG. 29 is a plan view of an absorbent article of the present disclosure

FIG. 30 is a cross sectional view of Section 29-29 of FIG. 28 .

FIG. 31 is a plan view of an absorbent article of the presentdisclosure.

FIG. 32 is a cross sectional view of Section 32-32 of FIG. 31 .

FIG. 33 is a plan view of an absorbent article of the presentdisclosure.

FIG. 34 is a cross sectional view of Section 34-34 of FIG. 33 .

FIG. 35 is a cross sectional view of Section 35-35 of FIG. 33 .

FIG. 36 is a photograph of an example of the present disclosure.

FIG. 37 is a photograph of an example of the present disclosure.

FIG. 38 is a photograph of an example of the present disclosure.

FIG. 39 is a photograph of cross section of the example shown in FIG. 38.

FIG. 40 is a Micro CT perspective view image of an example of thepresent disclosure.

FIG. 41 is a Micro CT perspective view image of an example of thepresent disclosure.

FIG. 42 is a Micro CT image of a cross section of the example shown inFIGS. 40 and 41 .

FIG. 43 is a Micro CT plan view image of the example shown in FIGS. 40and 41 .

FIG. 44 is a graphical depiction of various benefits of the invention ofthe present disclosure.

FIG. 45 is a photograph view image of a portion of an example of thepresent disclosure.

FIG. 46 is a photograph view image of a portion of an example of theinvention of the present disclosure.

FIG. 47 is a photograph view image of a portion of an example of theinvention of the present disclosure.

FIG. 48 is a photograph view image of a portion of an example of theinvention of the present disclosure.

FIG. 49 is a photograph of a cross section of the example shown in FIGS.47 and 48 .

FIG. 50 is a photograph view image of a portion of an example of theinvention of the present disclosure.

FIG. 51 is a photograph view image of a portion of an example of theinvention of the present disclosure.

FIG. 52 is a photograph view image of a portion of an example of theinvention of the present disclosure.

FIG. 53 is a photograph view image of a portion of an example of theinvention of the present disclosure.

FIG. 54 is a Micro CT plan view image of the example shown in FIGS. 40and 41 after experiencing additional processing.

FIG. 55 is a graphical depiction of various benefits of the invention ofthe present disclosure shown in FIG. 54 .

FIG. 56 is a schematic representation of an apparatus for making afabric of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure provides a shaped nonwoven fabric directly formedon a shaped forming belt with continuous spunbond filaments in a singleforming process. The fabric of the present disclosure can assume a shapewhich corresponds to the shape of the forming belt. A fabric of thepresent disclosure made on a forming belt of the present disclosure in amethod of the present disclosure can be particularly beneficial for usein personal care articles, garments, medical products, and cleaningproducts. The shaped nonwoven fabric can be fluid permeable for use as atopsheet, backsheet nonwoven, acquisition layer, distribution layer, orother component layer for a diaper, or a topsheet, backsheet nonwoven,acquisition layer, distribution layer, or other component layer for asanitary napkin, a topsheet, backsheet nonwoven, acquisition layer,distribution layer, or other component layer for an adult incontinentpad or pant, or a pad for a floor cleaning implement.

The beneficial features of the nonwoven fabric will be described in someembodiments herein in the context of an overall area of the nonwovenfabric. The overall area can be an area determined by dimensionssuitable for certain uses, for which the various features of theinvention provide beneficial properties. For example, the overall areaof a fabric can be that of a fabric having dimensions making it suitablefor use as a topsheet, backsheet nonwoven, acquisition layer,distribution layer, or other component layer for a diaper, or atopsheet, backsheet nonwoven, acquisition layer, distribution layer, orother component layer for a sanitary napkin, a topsheet, backsheetnonwoven, acquisition layer, distribution layer, or other componentlayer for an adult incontinent pad or pant, or a pad for a floorcleaning implement. Thus, the overall area can be based on width andlength dimensions ranging from 3 cm wide to 50 cm wide and from 10 cmlong to 100 cm long, resulting in overall areas of from 30 cm² to 500cm². The aforementioned ranges include as if explicitly stated everyinteger dimension between the range boundaries. By way of example, anoverall area of 176 cm² defined by a width of 11 cm and a length of 16cm is disclosed in the above ranges. As will be understood from thedescription herein, the overall area of a shaped nonwoven fabric may bea smaller area than the area of the web of nonwoven material of which itis a part when it is commercially made. That is, in a given commerciallymade web of nonwoven material, there can be a plurality of shapednonwoven fabrics of the invention, each of the shaped nonwoven fabricsof the invention having an overall area less than the area of the web onwhich it is made.

Photographs of representative examples of shaped nonwoven fabrics 10 areshown in FIGS. 1-3 . The shaped nonwoven fabric 10 can be a spunbondnonwoven substrate having a first surface 12 and a second surface 14. InFIGS. 1-3 , second surface 14 is facing the viewer and is opposite thefirst surface 12, which is unseen in FIGS. 1-3 but is depicted in FIG. 4. The term “surface” is used broadly to refer to the two sides of a webfor descriptive purposes, and is not intended to infer any necessaryflatness or smoothness. Although the shaped nonwoven fabric 10 is softand flexible, it will be described in a flattened condition the contextof one or more X-Y planes parallel to the flattened condition, and whichcorrespond in web-making technology to the plane of the cross-machinedirection, CD, and machine direction, MD, respectively, as shown inFIGS. 1-3 . The length, L, in the MD and the width, W, in the CDdetermine the overall area A for the nonwoven fabric 10. As shown inFIG. 4 , which is a cross section of a portion of the nonwoven fabric 10shown in FIG. 1 , for descriptive purposes the three-dimensionalfeatures of the shaped nonwoven fabric are described as extendingoutwardly in a Z-direction from an X-Y plane of the first surface 16(see, FIG. 4 ). In an embodiment, a maximum dimension ofthree-dimensional features in the Z-direction can define the maximumdistance between the plane of the first surface 16 and an X-Y plane ofthe second surface 18, which distance can be measured as the averagecaliper AC of the nonwoven fabric 10. The average caliper can bedetermined via optical, non-contact means, or it can be determined byinstruments involving spaced apart flat plates that measure the caliperof the nonwoven placed between them under a predetermined pressure. Itis not necessary that all the three-dimensional features have the sameZ-direction maximum dimension, but a plurality of three-dimensionalfeatures can have substantially the same Z-direction maximum dimensiondetermined by the fiber laydown process and the properties of theforming belt, discussed below.

The exemplary fabrics shown in FIGS. 1-4 (as well as other fabricsdisclosed herein) are fluid permeable. In an embodiment the entirefabric can be considered fluid permeable. In an embodiment regions orzones (described below) can be fluid permeable. By fluid permeable asused herein with respect to the fabric is meant that the fabric has atleast one zone which permits liquid to pass through under in-useconditions of a consumer product. For example, if used as a topsheet ona disposable diaper, the fabric can have at least one zone having alevel of fluid permeability permitting urine to pass through to anunderlying absorbent core. By fluid permeable as used herein withrespect to a region is meant that the region exhibits a porous structurethat permits liquid to pass through.

As shown in FIGS. 1-4 , the nonwoven fabric 10 can have a regular,repeating pattern of a plurality of discrete, recognizably differentthree-dimensional features, including a first three-dimensional feature20 and a second three-dimensional feature 22, and a thirdthree-dimensional feature 24, as shown in FIGS. 2 and 3 . For example,in FIG. 1 , heart-shaped first three-dimensional feature 20 isrecognizably different from the smaller, generally triangular-shapedsecond three-dimensional feature 22. The recognizable differences can bevisual, such as recognizably different sizes and/or shapes.

The three-dimensional features of the nonwoven fabric 10 can be formedby depositing, such as by carding, air laying, spinning from solution,or melt spinning, fibers directly onto a forming belt having a patternof corresponding three-dimensional features. In one sense the nonwovenfabric 10 is molded onto a forming belt that determines the shapes ofthe three-dimensional features of the fabric 10. However, importantly,as described herein, the apparatus and method of the invention producethe nonwoven fabric 10 such that in addition to taking the shape of theforming belt, because of the attributes of the forming belt and theapparatus for forming the fabric, it is imparted with beneficialproperties for use in personal care articles, garments, medicalproducts, and cleaning products. Specifically, because of the nature ofthe forming belt and other apparatus elements, as described below, thethree-dimensional features of the nonwoven fabric 10 have intensiveproperties that can differ between first and second regions within amicrozone (described more fully below), or from feature to feature inways that provide for beneficial properties of the nonwoven fabric 10when used in personal care articles, garments, medical products, andcleaning products. For example, first three-dimensional feature 20 canhave a basis weight or density that is different from the basis weightor density of second three-dimensional feature 22, and both can have abasis weight or density that is different from that of thirdthree-dimensional feature 24, providing for beneficial aesthetic andfunctional properties related to fluid acquisition, distribution and/orabsorption in diapers or sanitary napkins.

The intensive property differential between the variousthree-dimensional features of nonwoven fabric 10 is believed to be dueto the fiber distribution and compaction resulting from the apparatusand method described below. The fiber distribution occurs during thefiber laydown process, as opposed to, for example, a post making processsuch as hydroentangling or embossing processes. Because the fibers arefree to move during a process such as a melt spinning process, with themovement determined by the nature of the features and air permeabilityof the forming belt and other processing parameters, the fibers arebelieved to be more stable and permanently formed in nonwoven fabric 10.

As can be seen in FIGS. 1-3 and as understood from the descriptionherein, the distinct three-dimensional features may be bounded byvisually discernible (with respect to the interior of athree-dimensional feature) regions that can be in the form of a closedfigure (such as the heart shape in FIGS. 1 and 3 , and the diamond shapeof FIGS. 2 and 3 ). The closed figure can be a curvilinear closed figuresuch as the heart shape in FIGS. 1 and 3 . The outlining visuallydiscernible regions can be the regions of the nonwoven fabric 10 thatare most closely adjacent in the Z-direction to first surface 12, suchas regions 21 as shown in FIG. 4 , and with can lie at least partiallyin or on first plane 16 when in a flattened condition. For example, asshown in FIG. 1 , first three-dimensional feature 20 is heart shaped,and as indicated as one exemplary first three-dimensional feature 20A isdefined by a curvilinear closed heart-shaped element. A curvilinearelement can be understood as a linear element having at any point alongits length a tangential vector V, with the closed shape being such thatthe tangential vector V has both MD and CD components that change valuesover greater than 50% of the length of the linear element of the closedfigure. Of course, the figure need not be entirely 100% closed, but thelinear element can have breaks that do not take away from the overallimpression of a closed figure. As discussed below in the context of theforming belt, the outlining visually discernible curvilinear closedheart-shaped element is formed by a corresponding closed heart-shapedraised element on the forming belt to make the closed figure of a hearton fabric 10. In a repeating pattern, the individual shapes (in the caseof first three-dimensional feature in FIG. 1 , a heart shape) can resultin aesthetically pleasing, soft, pillowy features across the overallarea OA of the second surface 14 of fabric 10. In an embodiment in whichthe nonwoven fabric 10 is used as a topsheet for a diaper or sanitarynapkin, the second surface 14 of nonwoven fabric 10 can be body-facingto deliver superior aesthetic and performance benefits related tosoftness, compression resistance, and fluid absorption.

Specifically, in the regular repeating pattern of closed,three-dimensional features shown in FIG. 1-3 , it is believed, withoutbeing bound by theory, that the dimensions of the various features, theaverage basis weight of the entire fabric 10 across its overall area,and other processing parameters described below which define thediffering intensive properties contribute to a beneficial improvement incompression recovery. It is believed that the plurality of relativelyclosely spaced, relatively small, and relatively pillowythree-dimensional features act as springs to resist compression andrecover once a compressive force is removed. Compression recovery isimportant in topsheets, backsheet nonwovens, acquisition layers,distribution layers, or other component layers of personal care articlessuch as diapers, sanitary napkins, or adult incontinent pads, diapers,or pants for example, because such articles are typically packaged andfolded in compressed conditions. Manufacturers of personal care productsdesire to retain most, if not all of the as-made caliper for aestheticand performance purposes. The three-dimensionality of formed featuresprovide important aesthetic benefits due to the look and feel ofsoftness and pleasing appearance of crisp, well-defined shapes,including very small shapes such as the small hearts shown in FIG. 2 .The three-dimensional features also provide for softness during use,improved absorbency, less leakage, and overall improved in-useexperience. But the necessary compression during folding, packaging,shipping and storing of the personal care articles can cause permanentloss of caliper of a topsheet, backsheet nonwovens, acquisition layers,distribution layers, or other component layers of the absorbent articlethereby degrading the as-made functional benefits. We have foundunexpectedly the nonwoven fabrics of the present disclosure retain to asignificant degree their as made three-dimensional features even afterundergoing compression packaging and distribution in a compressionpackaged state.

Table 1 below shows compression recovery data for two embodiments of thepresent disclosure. Example 1 corresponds to the nonwoven fabric 10shown in FIG. 1 and made on a forming belt as described with referenceto FIGS. 12 and 14 . Example 2 corresponds to the nonwoven fabric 10shown in FIG. 2 and made on a forming belt as described with referenceto FIGS. 15 and 16 . As can be seen from the data, the fabrics 10 of theinvention show a significant benefit with respect to compressionrecovery when measured by the Compression Aging Test. In a form,packages of the absorbent articles having the compression recoverycharacteristics of the present disclosure can have a reduced in-bagstack height yet still deliver the aesthetic, absorbency, and softnessbenefits of the as made diaper; or as if it were never compressionpackaged. This invention provides for reduced in-bag stack heightpackages which allow caregivers to easily handle and store the packageswhile also providing manufacturers with reduced distribution costs, bothachieved while maintaining as made aesthetics clarity, absorbency, orsoftness performance of the absorbent article.

Example 1

A bicomponent spunbond nonwoven fabric that was produced by spinning a50:50 ratio of polyethylene sheath (Aspun-6850-A obtained from Dowchemical company) and polypropylene core (PH-835 obtained fromLyondellBasell) in a trilobal fiber configuration, as shown in FIG. 6 ,which is a scanning electron micrograph (SEM) showing a cross section ofa bicomponent trilobal fiber. The nonwoven fabric was spun on a formingbelt having a repeating pattern as described in FIG. 12 as describedbelow with respect to FIGS. 7 and 8 moving at a linear speed of about 25meters per minute to an average basis weight of 30 grams per squaremeter with a repeating pattern of heart shapes as shown in FIG. 1 .Fibers of the fabric were further bonded on first side 12 by heatedcompaction rolls 70, 72 (described below) at 130° C., and being wound onto a reel at winder 75.

Example 2

A bicomponent spunbond nonwoven fabric was produced by spinning a 50:50ratio of polyethylene sheath (Aspun-6850-A obtained from Dow chemicalcompany) and polypropylene core (PH-835 obtained from LyondellBasell) ina trilobal fiber configuration, as shown in FIG. 6 , which is a scanningelectron micrograph showing a cross section of a bicomponent trilobalfiber. The nonwoven fabric was spun on a forming belt having a repeatingpattern as described in FIG. 16 as described below with respect to FIGS.7 and 8 moving at a linear speed of about 25 meters per minute to form afabric 10 having an average basis weight of 30 grams per square meterwith a repeating pattern of diamond shapes as shown in FIG. 2 . Fibersof the fabric were further bonded on first surface 12 by heatedcompaction rolls 70, 72 (described below) at 130° C.

TABLE 1 Compression Recovery 4 KPa 14 KPa 35 KPa (~96 mm IBSH) (~84 mmIBSH) (~68 mm IBSH) Fresh Percent Percent Percent (Nonwoven CaliperCaliper Caliper Caliper Caliper Caliper 3-D off the roll) afterRetention after Retention after Retention Nonwoven Caliper Compression(%) Compression (%) Compression (%) Example 1 0.45 0.38 84.44 0.35 77.780.34 75.56 Example 2 0.43 0.36 83.72 0.36 83.72 0.31 72.09

As can be seen from Table 1, fabrics 10 of the invention retainsignificant amounts of caliper after compression at relatively highpressures. For example, the Example 1 and Example 2 samples retaingreater than 70% of their original average caliper after being tested bythe Compression Aging Test at a pressure of 35 KPa. The CompressionAging Test is a simulation of the conditions a nonwoven fabric wouldencounter if packaged in a high compression packaging of diapers andthen remain in such a state during distribution to a consumer and thenthe package finally opened by a consumer.

The present disclosure can utilize the process of melt spinning. In meltspinning, there is no mass loss in the extrudate. Melt spinning isdifferentiated from other spinning, such as wet or dry spinning fromsolution, where a solvent is being eliminated by volatilizing ordiffusing out of the extrudate resulting in a mass loss.

Melt spinning can occur at from about 150° C. to about 280°, or, in someembodiments, at from about 190° to about 230°. Fiber spinning speeds canbe greater than 100 meters/minute, and can be from about 1,000 to about10,000 meters/minute, and can be from about 2,000 to about 7,000meters/minute, and can be from about 2,500 to about 5,000 meters/minute.Spinning speeds can affect the brittleness of the spun fiber, and, ingeneral, the higher the spinning speed, the less brittle the fiber.Continuous fibers can be produced through spunbond methods ormeltblowing processes.

A nonwoven fabric 10 of the present disclosure can include continuousmulticomponent polymeric filaments comprising a primary polymericcomponent and a secondary polymeric component. The filaments can becontinuous bicomponent filaments comprising a primary polymericcomponent A and a secondary polymeric component B. The bicomponentfilaments have a cross-section, a length, and a peripheral surface. Thecomponents A and B can be arranged in substantially distinct zonesacross the cross-section of the bicomponent filaments and can extendcontinuously along the length of the bicomponent filaments. Thesecondary component B constitutes at least a portion of the peripheralsurface of the bicomponent filaments continuously along the length ofthe bicomponent filaments. The polymeric components A and B can be meltspun into multicomponent fibers on conventional melt spinning equipment.The equipment will be chosen based on the desired configuration of themulticomponent. Commercially available melt spinning equipment isavailable from Hills, Inc. located in Melbourne, Fla. The temperaturefor spinning range from about 180° C. to about 230° C. The processingtemperature is determined by the chemical nature, molecular weights andconcentration of each component. The bicomponent spunbond filaments canhave an average diameter from about 6 to about 40 microns, andpreferably from about 12 to about 40 microns.

The components A and B can be arranged in either a side-by-sidearrangement as shown in FIG. 5A or an eccentric sheath/core arrangementas shown in FIG. 5B to obtain filaments which exhibit a natural helicalcrimp. Alternatively, the components A and B can be arranged in aconcentric sheath core arrangement as shown in FIG. 5C. Additionally,the component A and B can be arranged in multi-lobal sheath corearrangement as shown in FIG. 6 . Other multicomponent fibers can beproduced by using the compositions and methods of the presentdisclosure. The bicomponent and multicomponent fibers may be segmentedpie, ribbon, islands-in-the-sea configuration, or any combinationthereof. The sheath may be continuous or non-continuous around the core.The ratio of the weight of the sheath to the core is from about 5:95 toabout 95:5. The fibers of the present disclosure may have differentgeometries that include round, elliptical, star shaped, rectangular, andother various eccentricities.

Methods for extruding multicomponent polymeric filaments into sucharrangements are well-known to those of ordinary skill in the art.

A wide variety of polymers are suitable to practice the presentdisclosure including polyolefins (such as polyethylene, polypropyleneand polybutylene), polyesters, polyamides, polyurethanes, elastomericmaterials and the like. Non-limiting examples of polymer materials thatcan be spun into filaments include natural polymers, such as starch,starch derivatives, cellulose and cellulose derivatives, hemicellulose,hemicelluloses derivatives, chitin, chitosan, polyisoprene (cis andtrans), peptides, polyhydroxyalkanoates, and synthetic polymersincluding, but not limited to, thermoplastic polymers, such aspolyesters, nylons, polyolefins such as polypropylene, polyethylene,polyvinyl alcohol and polyvinyl alcohol derivatives, sodium polyacrylate(absorbent gel material), and copolymers of polyolefins such aspolyethylene-octene or polymers comprising monomeric blends of propyleneand ethylene, and biodegradable or compostable thermoplastic polymerssuch as polylactic acid filaments, polyvinyl alcohol, filaments, andpolycaprolactone filaments. In one example, thermoplastic polymerselected from the group consisting of: polypropylene, polyethylene,polyester, polylactic acid, polyhydroxyalkanoate, polyvinyl alcohol,polycaprolactone, styrene-butadiene-styrene block copolymer,styrene-isoprene-styrene block copolymer, polyurethane, and mixturesthereof. In another example, the thermoplastic polymer is selected fromthe group consisting of: polypropylene, polyethylene, polyester,polylactic acid, polyhydroxyalkanoate, polyvinyl alcohol,polycaprolactone, and mixtures thereof. Alternatively, the polymer cancomprise one derived from monomers which are biobased such asbio-polyethylene or bio-polypropylene.

Primary component A and secondary component B can be selected so thatthe resulting bicomponent filament is providing improved nonwovenbonding and substrate softness. Primary polymer component A has meltingtemperature which is lower than the melting temperature of secondarypolymer component B.

Primary polymer component A can comprise polyethylene or randomcopolymer of propylene and ethylene. Secondary polymer component B cancomprise polypropylene or random copolymer of propylene and ethylene.Polyethylenes include linear low density polyethylene and high densitypolyethylene. In addition, secondary polymer component B may compriseadditives for enhancing the natural helical crimp of the filaments,lowering the bonding temperature of the filaments, and enhancing theabrasion resistance, strength and softness of the resulting fabric.

Inorganic fillers such as the oxides of magnesium, aluminum, silicon,and titanium may be added as inexpensive fillers or processing aides.Other inorganic materials include hydrous magnesium silicate, titaniumdioxide, calcium carbonate, clay, chalk, boron nitride, limestone,diatomaceous earth, mica glass quartz, and ceramics.

The filaments of the present invention also contain a slip additive inan amount sufficient to impart the desired haptics to the fiber. As usedherein “slip additive” or “slip agent” means an external lubricant. Theslip agent when melt-blended with the resin gradually exudes or migratesto the surface during cooling or after fabrication, hence forming auniform, invisibly thin coating thereby yielding permanent lubricatingeffects. The slip agent is preferably a fast bloom slip agent, and canbe a hydrocarbon having one or more functional groups selected fromhydroxide, aryls and substituted aryls, halogens, alkoxys, carboxylates,esters, carbon unsaturation, acrylates, oxygen, nitrogen, carboxyl,sulfate and phosphate.

During the making or in a post-treatment or even in both, the nonwovenfabrics of the present invention can be treated with surfactants orother agents to either hydrophilize the web or make it hydrophobic. Thisis standard practice for nonwovens used in absorbent articles. Forexample, a nonwoven fabric used for a topsheet may be treated with ahydrophilizing material or surfactant so as to make it permeable to bodyexudates such as urine. For other absorbent articles, the topsheet mayremain at its naturally hydrophobic state or made even more hydrophobicthrough the addition of a hydrophobizing material or surfactant.

Suitable materials for preparing the multicomponent filaments of thefabric of the present disclosure include PH-835 polypropylene obtainedfrom LyondellBasell and Aspun-6850-A polyethylene obtained from Dowchemical company.

When polyethylene is component A (sheath) and polypropylene is componentB (core), the bicomponent filaments may comprise from about 5 to about95% by weight polyethylene and from about 95 to about 5% polypropylene.The filaments can comprise from about 40 to about 60% by weightpolyethylene and from about 60 to about 40% by weight polypropylene.

Turning to FIG. 7 , a representative process line 30 for preparingfabrics 10 of the present disclosure is disclosed. The process line 30is arranged to produce a fabric of bicomponent continuous filaments, butit should be understood that the present disclosure comprehends nonwovenfabrics made with monocomponent or multicomponent filaments having morethan two components. Bicomponent filaments may be trilobal.

The process line 30 includes a pair of extruders 32 and 34 driven byextruder drives 31 and 33, respectively, for separately extruding theprimary polymer component A and the secondary polymer component B.Polymer component A is fed into the respective extruder 32 from a firsthopper 36 and polymer component B is fed into the respective extruder 34from a second hopper 38. Polymer components A and B can be fed from theextruders 32 and 34 through respective polymer conduits 40 and 42 tofilters 44 and 45 and melt pumps 46 and 47, which pump the polymer intoa spin pack 48. Spinnerets for extruding bicomponent filaments arewell-known to those of ordinary skill in the art and thus are notdescribed here in detail.

Generally described, the spin pack 48 includes a housing which includesa plurality of plates stacked one on top of the other with a pattern ofopenings arranged to create flow paths for directing polymer componentsA and B separately through the spinneret. The spin pack 48 has openingsarranged in one or more rows. The spinneret openings form a downwardlyextending curtain of filaments when the polymers are extruded throughthe spinneret. For the purposes of the present disclosure, spinneretsmay be arranged to form sheath/core or side-by-side bicomponentfilaments illustrated in FIGS. 5A, 5B, and 5C, as well as non-roundfibers, such as tri-lobal fibers as shown in FIG. 6 . Moreover, thefibers may be monocomponent comprising one polymeric component such aspolypropylene.

The process line 30 also includes a quench blower 50 positioned adjacentthe curtain of filaments extending from the spinneret. Air from thequench air blower 50 quenches the filaments extending from thespinneret. The quench air can be directed from one side of the filamentcurtain or both sides of the filament curtain.

An attenuator 52 is positioned below the spinneret and receives thequenched filaments. Fiber draw units or aspirators for use asattenuators in melt spinning polymers are well-known. Suitable fiberdraw units for use in the process of the present disclosure include alinear fiber attenuator of the type shown in U.S. Pat. No. 3,802,817 andeductive guns of the type shown in U.S. Pat. Nos. 3,692,618 and3,423,266, the disclosures of which are incorporated herein byreference.

Generally described, the attenuator 52 includes an elongate verticalpassage through which the filaments are drawn by aspirating air enteringfrom the sides of the passage and flowing downwardly through thepassage. A shaped, endless, at least partially foraminous, forming belt60 is positioned below the attenuator 52 and receives the continuousfilaments from the outlet opening of the attenuator 52. The forming belt60 is a belt and travels around guide rollers 62. A vacuum 64 positionedbelow the forming belt 60 where the filaments are deposited draws thefilaments against the forming surface. Although the forming belt 60 isshown as a belt in FIG. 8 , it should be understood that the formingbelt can also be in other forms such as a drum. Details of particularshaped forming belts are explained below.

In operation of the process line 30, the hoppers 36 and 38 are filledwith the respective polymer components A and B. Polymer components A andB are melted and extruded by the respective extruders 32 and 34 throughpolymer conduits 40 and 42 and the spin pack 48. Although thetemperatures of the molten polymers vary depending on the polymers used,when polyethylene and polypropylene are used as primary component A andsecondary component B respectively, the temperatures of the polymers canrange from about 190° C. to about 240° C.

As the extruded filaments extend below the spinneret, a stream of airfrom the quench blower 50 at least partially quenches the filaments,and, for certain filaments, to induce crystallization of moltenfilaments. The quench air can flow in a direction substantiallyperpendicular to the length of the filaments at a temperature of about0° C. to about 35° C. and a velocity from about 100 to about 400 feetper minute. The filaments can be quenched sufficiently before beingcollected on the forming belt 60 so that the filaments can be arrangedby the forced air passing through the filaments and forming surface.Quenching the filaments reduces the tackiness of the filaments so thatthe filaments do not adhere to one another too tightly before beingbonded and can be moved or arranged on the forming belt duringcollection of the filaments on the forming belt and formation of theweb.

After quenching, the filaments are drawn into the vertical passage ofthe attenuator 52 by a flow of the fiber draw unit. The attenuator iscan be positioned 30 to 60 inches below the bottom of the spinneret.

The filaments can be deposited through the outlet opening of theattenuator 52 onto the shaped, traveling forming belt 60. As thefilaments are contacting the forming surface of the forming belt 60, thevacuum 64 draws the air and filaments against the forming belt 60 toform a nonwoven web of continuous filaments which assumes a shapecorresponding to the shape of the forming surface. As discussed above,because the filaments are quenched, the filaments are not too tacky andthe vacuum can move or arrange the filaments on the forming belt 60 asthe filaments are being collected on the forming belt 60 and formed intothe fabric 10.

The process line 30 further includes one or more bonding devices such asthe cylinder-shaped compaction rolls 70 and 72, which form a nip throughwhich the fabric can be compacted. i.e., calendared, and which can beheated to bond fibers as well. One or both of compaction rolls 70, 72can be heated to provide enhanced properties and benefits to thenonwoven fabric 10 by bonding portions of the fabric. For example, it isbelieved that heating sufficient to provide thermal bonding improves thefabric's 10 tensile properties. The compaction rolls may be pair ofsmooth surface stainless steel rolls with independent heatingcontrollers. The compaction rolls may be heated by electric elements orhot oil circulation. The gap between the compaction rolls can behydraulically controlled to impose desired pressure on the fabric as itpasses through the compaction rolls on the forming belt. In anembodiment, with a forming belt caliper of 1.4 mm, and a spunbondnonwoven having a basis weight of 30 gsm, the nip gap between thecompaction rolls 70 and 72 can be about 1.4 mm.

In an embodiment, upper compaction roll 70 can be heated sufficient tomelt bond fibers on the first surface 12 of the fabric 10, to impartstrength to the fabric so that it can be removed from forming belt 60without losing integrity. As shown in FIGS. 8 and 9 , for example, asrolls 70 and 72 rotate in the direction indicated by the arrows, belt 60with the spunbond fabric laid down on it enter the nip formed by rolls70 and 72. Heated roll 70 can heat the portions of nonwoven fabric 10that are pressed against it by the raised resin elements of belt 60,i.e., in regions 21, to create bonded fibers 80 on at least firstsurface 12 of fabric 10. As can be understood by the description herein,the bonded regions so formed can take the pattern of the raised elementsof forming belt 60. For example, the bonded areas so formed can be asubstantially continuous network or a substantially semi-continuousnetwork on first surface 12 of regions 21 that make the same pattern asthe hearts of FIG. 1 and FIG. 11 . By adjusting temperature and dwelltime, the bonding can be limited primarily to fibers closest to firstsurface 12, or thermal bonding can be achieved to second surface 14 asshown in FIG. 11 (which also shows point bonds 90, discussed more fullybelow), and FIGS. 45-49 . Bonding can also be a discontinuous network,for example, as point bonds 90, discussed below.

The raised elements of the forming belt 60 may be selected to establishvarious network characteristics of the forming belt and the bondedregions of the nonwoven substrate 11 or nonwoven fabric 10. The networkcorresponds to the resin making up the raised elements of the formingbelt 60 and may comprise substantially continuous, substantiallysemi-continuous, discontinuous, or combinations thereof options. Thesenetworks may be descriptive of the raised elements of the forming belt60 as it pertains to their appearance or make-up in the X-Y planes ofthe forming belt 60 or the three dimensional features comprising thenonwoven substrate 11 or nonwoven fabric 10 of the present invention.

“Substantially continuous” network refers to an area within which onecan connect any two points by an uninterrupted line running entirelywithin that area throughout the line's length. That is, thesubstantially continuous network has a substantial “continuity” in alldirections parallel to the first plane and is terminated only at edgesof that region. The term “substantially,” in conjunction withcontinuous, is intended to indicate that while an absolute continuitycan be achieved, minor deviations from the absolute continuity may betolerable as long as those deviations do not appreciably affect theperformance of the fibrous structure (or a molding member) as designedand intended.

“Substantially semi-continuous” network refers an area which has“continuity” in all, but at least one, directions parallel to the firstplane, and in which area one cannot connect any two points by anuninterrupted line running entirely within that area throughout theline's length. The semi-continuous framework may have continuity only inone direction parallel to the first plane. By analogy with thecontinuous region, described above, while an absolute continuity in all,but at least one, directions is preferred, minor deviations from such acontinuity may be tolerable as long as those deviations do notappreciably affect the performance of the fibrous structure.

“Discontinuous” network refer to discrete, and separated from oneanother areas that are discontinuous in all directions parallel to thefirst plane.

After compaction, the fabric can leave the forming belt 60 and becalendared through a nip formed by calendar rolls 71, 73, after whichthe fabric can be wound onto a reel. As shown in the schematic crosssection of FIG. 10 , the calendar rolls can be stainless steel rollshaving an engraved pattern roll 84 and a smooth roll 86. The engravedroll can have raised portions 88 that can provide for additionalcompaction and bonding to the fabric 10. Raised portions 88 can be aregular pattern of relatively small spaced apart “pins” that form apattern of relatively small point bonds 90 in the nip of calendar rolls71 and 73. The percent of point bonds in the nonwoven fabric 10 can befrom 3% to 30% or from 7% to 20%. The engraved pattern can be aplurality of closely spaced, regular, generally cylindrically-shaped,generally flat-topped pin shapes, with pin heights being in a range fromranging 0.5 mm to 5 mm and preferably from 1 mm to 3 mm. Pin bondingcalendar rolls can form closely spaced, regular point bonds 90 innonwoven fabric 10, as shown in FIG. 11 . Further bonding can be byhot-air through bonding, for example.

As described with respect to FIG. 56 below, through-air thermal bondingmay be another approach to create higher loft nonwoven structures whichmay be suitable for this application. Through-air thermal bondinginvolves the application of hot air to the surface of the nonwovenfabric. The hot air flows through holes in a plenum positioned justabove the nonwoven. However, the air is not pushed through the nonwoven,as in common hot air ovens. Negative pressure or suction, pulls the airthrough the open conveyor apron that supports the nonwoven as it passesthorough the oven. Pulling the air through the nonwoven fabric allowsmuch more rapid and even transmission of heat and minimizes fabricdistortion. Aside from conventional through air bonding units, one couldenvision placing the bonding unit on top of the 3D belt while a vacuumis set under the belt to mimic the process of through air bonding forthis specific application.

Binders used in through-air thermal bonding include crystalline binderfibers, bi-component binder fibers, and powders. When using crystallinebinder fibers or powders, the binder melts entirely and forms moltendroplets throughout the nonwoven's cross-section. Bonding occurs atthese points upon cooling. In the case of sheath/core binder fibers, thesheath is the binder and the core is the carrier fiber. In oneembodiment, a nonwoven comprising sheath/core binder fibers, the sheathcomprises a polyethylene and the core comprises polypropylene. For sucha nonwoven, the through-air thermal bonding air temperature may be inthe range of 110° C. to 150° C. and the residence time may be in therange of 0.5 to 10 seconds, 5-30 seconds, or 30-60 seconds as throughair bonding time will depend upon basis weight, level of strengthdesired, and operating speed. Products manufactured using through-airovens tend to be bulky, open, soft, strong, extensible, breathable andabsorbent.

Point bonding as used herein is a method of thermally bonding a nonwovenfabric, web, or substrate. This method involves passing a web through anip between two rolls consisting of heated male patterned or engravedmetal roll and a smooth or patterned metal roll. The male patterned rollcan have a plurality of raised, generally cylindrical-shaped pins thatproduce circular point bonds. The smooth roll may or may not be heated,depending on the application. In a nonwoven production line, thenonwoven fabric, which could be a non-bonded fiber web, is fed into thecalendar nip and the fiber temperature is raised to the point for fibersto thermally fuse with each other at the tips of engraved points andagainst the smooth roll. The heating time is typically in the order ofmilliseconds. The fabric properties are dependent on process settingssuch as roll temperatures, web line speeds, and nip pressures, all ofwhich can be determined by the skilled person for the desired level ofpoint bonding. Other types of point bonding known generally as hotcalendar bonding may consist of different geometries for the bonds(other than circular shaped), such as oval, lines, circles, etc. In theexemplary embodiment disclosed herein, the point bonding produces apattern of point bonds being 0.5 mm diameter circles with 10% overallbonding area. Other embodiments comprise bonding shapes where the raisedpins have a longest dimension across the bonding surface of a pin offrom about 0.1 mm to 2.0 mm and the overall bonding area ranges from 5%to 30%.

As shown in FIG. 11 , in an embodiment, heated compaction roll 70 canform a bond pattern, which can be a substantially continuous networkbond pattern 80 (e.g., interconnected heart shaped bonds) on firstsurface 12 of nonwoven fabric 10 (not shown in FIG. 11 , as it facesaway from the viewer), and engraved calendar roll 73 can form relativelysmall point bonds 90 on second surface 14 of fabric 10. The point bonds90 secure loose fibers that would otherwise be prone to fuzzing orpilling during use of the fabric 10. The advantage of the resultingstructure of nonwoven fabric 10 is most evident when used as a topsheetin a personal care article such as a diaper or sanitary napkin. In usein a personal care article, the first surface 12 of nonwoven fabric 10can be relatively flat (relative to second surface 14) and have arelatively large amount of bonding due to the heated compaction rollforming bonds 80 at the areas of the fabric pressed by the raisedelements of forming belt 60. This bonding gives the nonwoven fabric 10structural integrity, but can be relatively stiff or rough to the skinof a user. Therefore, the first surface 12 of the nonwoven fabric 10 canbe oriented in a diaper or sanitary napkin to face the interior of thearticle. i.e., away from the body of the wearer. Likewise, the secondsurface 14 can be body facing in use, and in contact with the body. Therelatively small point bonds 90 are less likely to be perceived visuallyor tactiley by the user, and the relatively soft three-dimensionalfeatures remain visually free of fuzzing and pilling while feeling softto the body in use. Further bonding can be used instead of, or inaddition to, the above mentioned bonding.

Forming belt 60 can be made according to the methods and processesdescribed in U.S. Pat. No. 6,610,173, issued to Lindsay et al. on Aug.26, 2003, or U.S. Pat. No. 5,514,523 issued to Trokhan et al. on May 7,1996, or U.S. Pat. No. 6,398,910 issued to Burazin et al. on Jun. 4,2002, or US Pub. No. 2013/0199741, published in the name of Stage et al.on Aug. 8, 2013, each with the improved features and patterns disclosedherein for making spunbond nonwoven webs. The Lindsay. Trokhan, Burazinand Stage disclosures describe belts that are representative ofpapermaking belts made with cured resin on a woven reinforcing member,which belts, with improvements, can be utilized in the presentdisclosure as described herein.

An example of a forming belt 60 of the type useful in the presentdisclosure and which can be made according to the disclosure of U.S.Pat. No. 5,514,523, is shown in FIG. 12 . As taught therein, areinforcing member 94 (such as a woven belt of filaments 96) isthoroughly coated with a liquid photosensitive polymeric resin to apreselected thickness. A film or negative mask incorporating the desiredraised element pattern repeating elements (e.g., FIG. 14 ) is juxtaposedon the liquid photosensitive resin. The resin is then exposed to lightof an appropriate wave length through the film, such as UV light for aUV-curable resin. This exposure to light causes curing of the resin inthe exposed areas (i.e., white portions or non-printed portions in themask). Uncured resin (resin under the opaque portions in the mask) isremoved from the system leaving behind the cured resin forming thepattern illustrated, for example, the cured resin elements 92 shown inFIG. 12 . Other patterns can also be formed, as discussed herein.

FIG. 12 shows a portion of a forming belt 60 useful for making thenonwoven fabric 10 shown in FIG. 1 . As shown, the forming belt 60 caninclude cured resin elements 92 on a woven reinforcing member 94. Thereinforcing member 94 can be made of woven filaments 96 as is known inthe art of papermaking belts, including resin coated papermaking belts.The cured resin elements can have the general structure depicted in FIG.12 , and are made by the use of a mask 97 having the dimensionsindicated in FIG. 14 . As shown in schematic cross-section in FIG. 13 ,cured resin elements 92 flow around and are cured to “lock on” toreinforcing member 94 and can have a width at a distal end DW of about0.020 inch to about 0.060 inch, or from about 0.025 inch to about 0.030inch, and a total height above the reinforcing member 94, referred to asover burden. OB, of about 0.030 inch to about 0.120 inch or about 0.50to about 0.80 inch, or about 0.060 inch. FIG. 14 represents a portion ofa mask 97 showing the design and representative dimensions for onerepeat unit of the repeating hearts design in the nonwoven fabric 10shown in FIG. 1 . The white portion 98 is transparent to UV light, andin the process of making the belt, as described in U.S. Pat. No.5,514,523, permits UV light to cure an underlying layer of resin whichis cured to form the raised elements 92 on the reinforcing member 94.After the uncured resin is washed away, the forming belt 60 having acured resin design as shown in FIG. 12 is produced by seaming the endsof a length of the belt, the length of which can be determined by thedesign of the apparatus, as depicted in FIG. 7 .

In like manner, FIG. 15 represents a portion of a mask 97 showing thedesign for one repeat unit of the repeating design in the nonwovenfabric 10 shown in FIG. 2 . The white portion 98 is transparent to UVlight, and in the process of making the belt permits UV light to cure anunderlying layer of resin which is cured to the reinforcing member 94.After the uncured resin is washed away, the forming belt 60 having acured resin design as shown in FIG. 16 is produced by seaming the endsof a length of the belt, the length of which can be determined by thedesign of the apparatus, as depicted in FIG. 7 .

Further, in another non-limiting example, FIG. 17 represents a portionof a mask showing the design for one repeat unit of the repeating designin the nonwoven fabric 10 shown in FIG. 18 . The white portion 98 istransparent to UV light, and in the process of making the belt permitsUV light to cure an underlying layer of resin which is cured to thereinforcing member 94. After the uncured resin is washed away, theforming belt 60 having a cured resin design as shown in FIG. 18 isproduced by seaming the ends of a length of fabric 10.

Another example of a portion of a forming belt 60 of the type useful inthe present disclosure is shown in FIG. 19 . The portion of the formingbelt 60 shown in FIG. 19 is a discrete belt pattern 61 that can have alength L and width W corresponding to the length L and width W of theoverall area OA of a nonwoven fabric 10. That is, the forming belt 60can have discrete belt patterns 61 (as discussed more fully withreference to FIG. 22 below), each having a discrete belt pattern overallarea DPOA that corresponds to the overall area OA of the nonwoven fabric10. FIG. 20 represents a portion of a mask showing the design for onerepeat unit of the repeating design in the nonwoven fabric 10 shown inFIG. 21 . The white portion 98 is transparent to UV light, and in theprocess of making the belt permits UV light to cure an underlying layerof resin which is cured to the reinforcing member 94. After the uncuredresin is washed away, the forming belt 60 having a cured resin design asshown in FIG. 19 is produced by seaming the ends of a length of thebelt.

The portion of the forming belt shown in FIG. 19 illustrates anotherbenefit of the present disclosure. The portion of a forming belt 60shown in FIG. 19 can make a fabric 10 shown in FIG. 21 . The nonwovenfabric 10 shown in FIG. 21 can have width W and length L dimensions andan overall area OA making it suitable for use as a topsheet in adisposable diaper, for example. The nonwoven fabric 10 made on a formingbelt 60 as exemplified in FIG. 19 differs from that shown in FIGS. 1-3in that the pattern of three-dimensional features formed by the discreteresin elements 92 on forming belt 60 are not in a regular, repeatingpattern across the entire overall area. Rather, the pattern ofthree-dimensional raised elements in the discrete belt pattern overallarea DPOA can be described as an irregular pattern encompassing distinctportions referred to as zones. The distinction between zones can bevisual. i.e., a visually discernible difference, or in the nonwovenfabric 10 the distinction can produce a difference in average intensiveproperties such as basis weight or density, or combinations of visualand intensive properties. A visually discernible difference exists if anobserver in ordinary indoor lighting conditions (20/20 vision, lightingsufficient to read by, for example) can visually discern a patterndifference between the zones, such as the first zone 112 and the secondzone 122.

The nonwoven fabric 10 can also have visually discernible zonescorresponding to the zones of the forming belt. As shown in FIG. 21 ,for example, fabric 10 can have at least two, three, or four visuallydiscernible zones. A first zone 110, having first pattern ofthree-dimensional features and first average intensive properties, canhave a first area generally centrally located within the overall areaOA. A second zone 120, having second pattern of three-dimensionalfeatures and second average intensive properties, can have a second areadistributed generally about, and in an embodiment, completelysurrounding, the first zone 110 within the overall area OA. A third zone130, having third pattern of three-dimensional features and thirdaverage intensive properties, can have a third area distributedgenerally about, and in an embodiment, completely surrounding, thesecond zone 120 within the overall area OA. A fourth zone 140, havingfourth three-dimensional features and fourth average intensiveproperties, can have a fourth area positioned within the overall area OAin any location, such as at a front area of a topsheet, such as theheart design shown in FIG. 21 . In general, there can be n zones, with nbeing a positive integer. Each of the n zones can have an nth pattern ofthree-dimensional features and an nth area and nth average intensiveproperties.

The visually discernible zones as shown in FIG. 21 may comprise visuallydiscernible three-dimensional features. These distinct three-dimensionalfeatures may be bounded by relatively higher density (with respect tothe interior of a three-dimensional feature) regions that may be in theform of a closed figure, such as the heart shape in FIGS. 1 and 3 , andthe diamond shape of FIGS. 2 and 3 . In general, as discussed more fullybelow, including in the context of micro zones, the three-dimensionalfeatures can be defined by a first region and a second region, whereinthe first region and second region are visually distinct and there is acommon intensive property associated with each of the first and secondregions and there is a difference in the first region's and secondregion's common intensive property value. In an embodiment, thethree-dimensional features can be defined by a first region and a secondregion, with the first region being at a higher elevation (dimensionmeasured in the Z-direction) than the second region with respect to theplane of the first surface. In another embodiment, the three-dimensionalfeatures can be defined by a first region and a second region, with thefirst region being at a higher basis than the second region.

As can be understood, rather than having a constant repeating patternthat is uniform across the entire forming belt, the forming belt 60 ofthe present disclosure allows the production of a nonwoven material thatcan have repeats of irregular discrete belt patterns 61, each discretebelt pattern 61 being like the discrete belt pattern shown in FIG. 19 .The discrete belt patterns 61 each can be used to form one nonwovenfabric 10 having an overall area OA suitable for use in a disposableabsorbent article, such as diaper or sanitary napkin, for example. Thenonwoven fabrics 10 can be produced sequentially, i.e., in line, and,optionally sequentially in parallel lanes, each lane being a sequentialline of nonwoven fabrics 10. The sequential line of nonwoven fabrics 10can be produced in a machine direction along an axis parallel to themachine direction. The nonwoven material can then be slit or otherwisecut to size to produce nonwoven fabrics 10 utilized as a topsheets indisposable absorbent articles, such as diapers or sanitary napkins.

In an embodiment, the pattern within each discrete belt pattern overallarea DPOA can be the same or different. That is, the sequentially spaceddiscrete belt patterns can be substantially identical, or they candiffer in visual appearance and/or in the intensive properties producedin nonwoven substrates produced thereon. For example, as shownschematically in FIG. 22 , the pattern of three-dimensional raisedelements in first forming zone 112 of discrete belt pattern 61A can bedifferent from the pattern of three-dimensional raised elements in firstforming zone 112 of discrete belt pattern 61B. The forming belt 60 thusoffers flexibility in producing nonwoven webs 10 suitable for use inconsumer goods, including disposable absorbent articles. For example, inone package of diapers, the topsheets of at least two diapers can bedifferent because they were produced sequentially in a spunbond processas described herein, with sequential discrete belt patterns havingdifferent patterns of zones. In an embodiment, the topsheet or backsheetnonwoven pattern for one size of diaper can be different from thetopsheet or backsheet nonwoven of another size of diaper, thereby givinga caretaker a visual clue as to the size of a diaper. Likewise, sanitarynapkins can utilize a fabric 10 for a topsheet, with the visual patternof three-dimensional features denoting the absorbency of the sanitarynapkin. In any event, the various patterns of fabrics 10 can be producedon a single belt by making the discrete belt patterns different asdesired.

Thus, the invention can be described, with reference to FIG. 22 , as aforming belt having an axis A parallel to a longitudinal direction whichis a machine direction. The forming belt 60 can have a plurality ofdiscrete belt patterns 61 ordered in at least one sequentialrelationship with respect to the longitudinal direction. Each discretebelt pattern 61 can have a discrete belt pattern overall area DPOAdefined, in a rectangular-shaped pattern, by a length L and width W, asindicated with respect to discrete belt pattern 61A. Each discrete beltpattern within its overall area DPOA can have a first forming zone 112having a first pattern of three-dimensional raised elements extendingoutwardly from the plane of the of the first surface and a secondforming zone 122 having second three-dimensional raised elementsextending outwardly from the plane of the of the first surface. Thefirst forming zone can have a first air permeability value and thesecond forming zone can have a second air permeability value, and thefirst air permeability value can be different from the second airpermeability value. The pattern within each sequentially ordereddiscrete belt pattern overall area DPOA can be the same or different.

By way of example, and referring to the discrete belt pattern 61 offorming belt 60 shown in FIG. 19 , and the nonwoven fabric 10 shown inFIG. 21 , the following properties were determined. First zone 110 ofnonwoven fabric 10 can have an average basis weight of about 5 gsm toabout 30 gsm; the second zone 120 can have an average basis weight ofabout 50 gsm to about 70 gsm; and the third zone 130 can have an averagebasis weight of about 25 gsm to about 60 gsm. The difference in basisweight from one zone to another can be attributed to a difference in airpermeability of the forming belt 60. In the embodiment used to make thenonwoven fabric 10 shown in FIG. 20 , in which the basis weights forzones 110, 120, and 130, are 15 gsm, 53 gsm and 25 gsm, respectively,the air permeability of the respective zones 112, 122, and 132 of theforming belt 60 are 379 cfm, 805 cfm, and 625 cfm, respectively. Thus,by varying air permeability in zones in forming belt 10, the intensiveproperties of average basis weight and average density in zones can befacilitated across the overall area of fabric 10.

As can be understood from the description of the forming belt 60described in FIG. 22 , and with reference to FIG. 23 , in an embodimentthe nonwoven substrate 11 made on belt 60 can be described as a nonwovensubstrate 11 having a plurality of portions described herein as fabrics10 ordered in at least one sequential relationship with respect to thelongitudinal direction, i.e., the machine direction when made on formingbelt 60. FIG. 23 is a schematic representation of a spunbond nonwovensubstrate 11 showing the sequentially ordered fabrics 10, each fabric 10having a different pattern within the various zones. Each fabric 10 canhave an overall area OA defined, in a rectangular-shaped pattern, by alength L and width W. Each sequentially disposed fabric 10 can havewithin its overall area OA at 5 least a first zone 110, having a firstpattern of three-dimensional features and first average intensiveproperties, and a first area located within the overall area OA; asecond zone 120, having a second pattern of three-dimensional featuresand second average intensive properties, having a second area locatedwithin the overall area OA. Optionally, more zones, e.g., a third zone130, having third pattern of three-dimensional features and thirdaverage intensive property and having a third area within the overallarea OA can be present. As shown in the exemplary schematicrepresentation of FIG. 23 , the first pattern 110A of fabric 10A can bedifferent from the first pattern 110B of fabric 10B, and can bedifferent from first pattern 110C of fabric 10C. The same can be truefor second zones 120A, 120B, and 120C.

In general, the sequentially ordered nonwoven fabrics 10 of the nonwovenmaterial 11 made on forming belt 60 can vary in their respective overallareas, intensive properties, and visual appearances. A common intensiveproperty is an intensive property possessed by more than one zone (withrespect to zonal patterns, such as that shown in FIG. 21 ) or region(for three-dimensional features such as the regular repeating patterns,such as that shown in FIG. 1 ). Such intensive properties of thenonwoven fabrics 10 can be average values, and can include, withoutlimitation, density, volumetric density, basis weight, thickness, andopacity. For example, if a density is a common intensive property of twodifferential zones or regions, a value of the density in one zone orregion can differ from a value of the density in the other zone orregion. Zones (such as, for example, a first zone and a second zone) canbe identifiable areas distinguishable from one another visually and bydistinct intensive properties averaged within the zone.

Once produced, the individual nonwoven fabrics 10 can be cut to size andutilized for their intended purposes, such as for topsheets indisposable absorbent articles. For example, a disposable diaper 1006 ina flattened orientation is shown in FIG. 24 . One fabric 10 is cut tothe appropriate overall area and adhered into the diaper 1006 by meansknown in the art. Fabrics 10 can be cut prior to being assembled into adiaper 1006, or during the diaper making process the nonwoven substrate11 can be brought together with other diaper components in web form, andcut to size after assembly.

As can be understood with reference to FIG. 24 , in an embodiment thenonwoven substrate 11 made on belt 60 can be described as a nonwovenfabric 11 having a plurality of portions described herein as fabrics 10ordered in at least one sequential relationship with respect to thelongitudinal direction. i.e., the machine direction when made on formingbelt 60, in at least one side-by-side relationship, i.e., in the crossmachine direction when made on forming belt 60. FIG. 24 is a schematicrepresentation of a spunbond nonwoven substrate 11 showing thesequentially ordered fabrics 10 in adjacent machine direction lanes 13,adjacent lanes having the side-by each fabrics 10, called out in FIG. 24as 10D, 10E, and 10F. Each fabric 10 can have an overall area OAdefined, in a rectangular-shaped pattern, by a length L and width W.Each sequentially disposed fabric 10 can have within its overall area OAat least a first zone 110, having a first pattern of three-dimensionalfeatures and first average intensive properties, and a first arealocated within the overall area OA; a second zone 120, having a secondpattern of three-dimensional features and second average intensiveproperties, having a second area located within the overall area OA.Optionally, more zones. e.g., a third zone 130, having third pattern ofthree-dimensional features and third average intensive property andhaving a third area within the overall area OA can be present. Eachfabric 10 in side-by-side lanes can be substantially identical, or theycan be different with respect to size, visual appearance, and/orintensive properties. Once produced, the nonwoven substrate 11 can bereeled for slitting into lanes for processing into consumer products, orslit and then reeled.

By way of representative sample to compare basis weight differentials ina fabric 10 made with a regular, repeating, uniform pattern and a fabric10 made with a non-uniform, zonal pattern, the nonwoven fabric 10 ofExample 1 was compared with a fabric having a pattern similar to thatshown in FIG. 21 , and referred to as Example 3. Example 3 is abicomponent spunbond nonwoven web produced on the apparatus disclosedherein by spinning 50:50 ratio of polyethylene sheath (Aspun-6850-Aobtained from Dow chemical company) and polypropylene core (PH-835obtained from LyondellBasell) in a trilobal fiber configuration. Thespunbond, bicomponent, trilobal fibers were laid down on a forming belt60 moving at a linear speed of about 25 meters per minute to an averagebasis weight of 30 grams per square meter on a forming belt with a zonalpattern as shown in FIG. 19 . The second substrate was formed underidentical conditions, but had at least one section having a regular,repeating, uniform pattern on a forming belt as shown in FIG. 16 , fromwhich basis weight was determined. Fiber spinning conditions,through-put, forming belt line speed and compaction roll bondingtemperature were identical for both substrates.

Example 3

A bicomponent spunbond nonwoven fabric that was produced by spinning a50:50 ratio of polyethylene sheath (Aspun-6850-A obtained from Dowchemical company) and polypropylene core (PH-835 obtained fromLyondellBasell) in a trilobal fiber configuration to an average basisweight of 30 grams per square meter. A nonwoven fabric was produced asdescribed with respect to FIGS. 7 and 8 moving at a forming belt linearspeed of about 25 meters per minute to form a fabric having zonalpattern as shown in FIG. 20 . Fibers of the fabric were further bondedon first surface 12 by heated compaction rolls 70, 72 at 130° C. and thefabric was wound on to a reel at winder 75.

Example 4

A bicomponent spunbond nonwoven fabric that was produced by spinning a50:50 ratio of polyethylene sheath (Aspun-6850-A obtained from Dowchemical company) and polypropylene core (PH-835 obtained fromLyondellBasell) in a trilobal fiber configuration to an average basisweight of 30 grams per square meter. A nonwoven fabric was produced asdescribed with respect to FIGS. 7 and 8 moving at a forming belt linearspeed of about 25 meters per minute to form a fabric having repeating(non-zonal) pattern as shown in FIG. 2 . Fibers of the fabric werefurther bonded on first surface 12 by heated compaction rolls 70, 72 at130° C., and being wound on to a reel at winder 75.

Table 2 below shows average local basis weight, measured according tothe Localized Basis Weight test method herein, and averaged over 10samples. The samples for measurement were taken from the fabrics asshown in FIGS. 25A and 25B, in which the dark rectangles are where a 3cm² sample was removed for measurement. As can be seen, the fabrics arelabeled across the cross-direction (CD) as A-E. The measurements shownnot only a significant difference in basis weight between zones of thezonal fabric, but a CD distribution which is depicted graphically inFIG. 26 .

TABLE 2 Measured Average Basis Weight distribution in nonwoven fabric 10in grams per square meter (gsm) Region as Example 3: Zonal Example 4:Non-zonal Depicted in Fabric Basis Fabric Basis FIG. 25 Weights weightsA 48 gsm 43 gsm B 79 gsm 37 gsm C 14 gsm 32 gsm D 65 gsm 36 gsm E 54 gsm36 gsm

As can be seen in Table 2, fabrics 10 made on forming belts 60 havingzones of differing air permeability demonstrate substantial variation infiber laydown and thus basis weights within the CD of nonwoven fabric 10suggesting the ability for fibers to travel with air into highpermeability zones. The non-zonal, regular repeating pattern fabric 10exhibits approximately the same basis weights within the CD of fabric.

In addition to differences in air permeability of the various zones ofthe forming belt 60, the structure of forming belt 60 can affect otherintensive properties of zones in the fabric 10, such as average caliper,average softness, average compression resistance, and fluid absorptionproperties.

Another aspect of this invention relates to spunbond commercial lineswhere multiple beams are utilized for improved laydown opacity anduniformity of the fabric. In some cases, there the apparatus can includetriple spunbond beams (known in the art as “SSS”) and may be combinedwith meltblown (M), for example, in an apparatus known as an “SSMMS”spunbond line.

By calendaring the nonwoven fabric 10 to have point bonds 90, fuzzingcan be reduced. Fuzzing refers to the tendency of fibers to become looseand removed from the fabric 10. Loosening and removal can be because offrictional engagement with manufacturing equipment during production ofdisposable absorbent articles, or another surface, such as the skin of aperson interacting with the fabric 10. In some uses, such as fortopsheets in disposable absorbent articles, fuzzing is a negativeconsumer phenomena. But bonding fibers in place can also be a consumernegative as it can produce roughness on the surface of an otherwise softnonwoven substrate. We have found expectedly the nonwoven fabricssubstrates and nonwoven fabrics of the present disclosure can endure anincrease in bonding (and a consequent decrease in fuzzing) with minimalloss in softness. Bonding can be accomplished by relatively closelyspaced point bonds 90, with the spacing being determined by the desiredlevel of fuzzing reduction. Bonding can also be achieved by knownmethods for chemically or thermally bonding nonwoven fibers, such asthermal bonding, ultrasonic bonding, pressure bonding, latex adhesivebonding, and combinations of such methods. Fuzz reduction by bonding isillustrated with respect to Examples 5 and 6 below.

Example 5

A bicomponent spunbond nonwoven fabric was produced by spinning a 50:50ratio of polyethylene sheath (Aspun-6850-A obtained from Dow chemicalcompany) and polypropylene core (PH-835 obtained from LyondellBasell) ina trilobal fiber configuration to an average basis weight of about 30grams per square meter on a forming belt as described with respect toFIGS. 7 and 8 moving at a linear speed of about 25 meters per minute toform a fabric having the repeating pattern as shown in FIG. 36 Fibers ofthe fabric were further bonded on first surface 12 by compaction rolls70, 72 with compaction roll 70 heated to 130° C. to form substantiallycontinuous bonds 80.

Example 6

A bicomponent spunbond nonwoven fabric was produced by spinning a 50:50ratio of polyethylene sheath (Aspun-6850-A obtained from Dow chemicalcompany) and polypropylene core (PH-835 obtained from LyondellBasell) ina trilobal fiber configuration to an average basis weight of about 30grams per square meter on a forming belt as described with respect toFIGS. 7 and 8 moving at a linear speed of about 25 meters per minute toform a fabric having the repeating pattern described with respect FIG.37 Fibers of the fabric were further bonded on first surface 12 bycompaction rolls 70, 72 with compaction roll 70 heated to 130° C. toform substantially continuous bonds 80. Fibers of the fabric werefurther calendar bonded at calendar rolls 71, 73, with roll 73 being anengraved roll having raised portions 88 in the form of pins with 1.25 mmpin height and 0.62 mm open gap in a 10% point bonding pattern. The roll73 was heated to 135 C to form point bonds 90 on second side 14 offabric 10, as shown in FIG. 11 .

The fabrics 10 of Examples 5 and 6 differed only in the absence orpresence of point bonds 90. The second side 14 of the fabrics 10underwent fuzz testing according to the Fuzz Level Test to determine theeffectiveness of the point bonds in securing fibers to the surface ofthe fabric. The results of fuzz testing of Examples 5 and 6 are shown inTable 3.

TABLE 3 MD Fuzz Results Sample No. MD Fuzz Value (mg/cm²) Example 5 0.36Example 6 0.19

As shown above, the point bonds 90 result in a dramatic decrease in theMD Fuzz Value. It unexpectedly retained its softness, absorbency, andaesthetic benefits in spite of the bonding treatment and now also hasthe desired resistance to fuzz upon consumer use. Present disclosureabsorbent articles are generally placed into packages for shipping,storing, and selling. The packages may comprise polymeric films and/orother materials. Graphics and/or indicia relating to properties of theabsorbent articles may be formed on, printed on, positioned on, and/orplaced on outer portions of the packages. Each package may comprise aplurality of absorbent articles. The absorbent articles may be packedunder compression so as to reduce the size of the packages, while stillproviding an adequate amount of absorbent articles per package. Bypackaging the absorbent articles under compression, caregivers caneasily handle and store the packages, while also providing distributionsavings to manufacturers owing to the size of the packages. FIG. 27illustrates an example package 1000 comprising a plurality of absorbentarticles 1004. The package 1000 defines an interior space 1002 in whichthe plurality of absorbent articles 1004 are situated. The plurality ofabsorbent articles 1004 are arranged in one or more stacks 1006.

Packages of the absorbent articles of the present disclosure may have anIn-Bag Stack Height of less than about 100 mm, less than about 95 mm,less than about 90 mm, less than about 85 mm, less than about 85 mm, butgreater than about 75 mm, less than about 80 mm, less than about 78 mm,less than about 76 mm, or less than about 74 mm, specifically recitingall 0.1 mm increments within the specified ranges and all ranges formedtherein or thereby, according to the In-Bag Stack Height Test describedherein. Alternatively, packages of the absorbent articles of the presentdisclosure may have an In-Bag Stack Height of from about 70 mm to about100 mm, from about 70 mm to about 95 mm, from about 72 mm to about 85mm, from about 72 mm to about 80 mm, or from about 74 mm to about 78 mm,specifically reciting all 0.1 mm increments within the specified rangesand all ranges formed therein or thereby, according to the In-Back StackHeight Test described herein.

General Description of an Absorbent Article

The three-dimensional nonwoven fabrics 10 of the present disclosure canbe utilized as a component of absorbent articles, such as diapers, childcare items such as training pants, feminine care items such as sanitarynapkins, and adult care items such as incontinence products, pads, andpants An example absorbent article in the form of a diaper 220 isrepresented in FIGS. 28-30 . FIG. 28 is a plan view of the examplediaper 220, in a flat, laid-out state, with portions of the structurebeing cut-away to more clearly show the construction of the diaper 220.The wearer-facing surface of the diaper 220 of FIG. 28 is facing theviewer. This diaper 220 is shown for illustration purpose only as thethree-dimensional nonwoven materials of the present disclosure may beused as one or more components of an absorbent article, such as thetopsheet, the acquisition layer, the topsheet and the acquisition layer,or the topsheet and the acquisition and/or the distribution system(“ADS”). In any event the three-dimensional nonwoven materials of thepresent disclosure may be liquid permeable.

The absorbent article 220 may comprise a liquid permeable material ortopsheet 224, a liquid impermeable material or backsheet 225, anabsorbent core 228 positioned at least partially intermediate thetopsheet 224 and the backsheet 225, and barrier leg cuffs 234. Theabsorbent article may also comprise an ADS 250, which in the examplerepresented comprises a distribution layer 254 and an acquisition layer252, which will be further discussed below. The absorbent article 220may also comprise elasticized gasketing cuffs 232 comprising elastics233 joined to a chassis of the absorbent article, typically via thetopsheet and/or backsheet, and substantially planar with the chassis ofthe diaper.

FIGS. 28 and 31 also show typical taped diaper components such as afastening system comprising tabs 242 attached towards the rear edge ofthe article and cooperating with a landing zone 244 on the front of theabsorbent article. The absorbent article may also comprise other typicalelements, which are not represented, such as a rear elastic waistfeature, a front elastic waist feature, transverse barrier cuff(s),and/or a lotion application, for example.

The absorbent article 220 comprises a front waist edge 210, a rear waistedge 212 longitudinally opposing the front waist edge 210, a first sideedge 203, and a second side edge 204 laterally opposing the first sideedge 203. The front waist edge 210 is the edge of the article which isintended to be placed towards the front of the user when worn, and therear waist edge 212 is the opposite edge. The absorbent article 220 mayhave a longitudinal axis 280 extending from the lateral midpoint of thefront waist edge 210 to a lateral midpoint of the rear waist edge 212 ofthe article and dividing the article in two substantially symmetricalhalves relative to the longitudinal axis 280, with the article placedflat, laid-out and viewed from above as in FIG. 28 . The absorbentarticle 220 may also have a lateral axis 290 extending from thelongitudinal midpoint of the first side edge 203 to the longitudinalmidpoint of the second side edge 204. The length. L. of the article maybe measured along the longitudinal axis 280 from the front waist edge210 to the rear waist edge 212. The width, W, of the absorbent articlemay be measured along the lateral axis 290 from the first side edge 203to the second side edge 204. The absorbent article may comprise a crotchpoint C defined herein as the point placed on the longitudinal axis at adistance of two fifth (⅖) of L starting from the front edge 210 of thearticle 220. The article may comprise a front waist region 205, a rearwaist region 206, and a crotch region 207. The front waist region 205,the rear waist region 206, and the crotch region 207 may each define ⅓of the longitudinal length. L. of the absorbent article.

The topsheet 224, the backsheet 225, the absorbent core 228, and theother article components may be assembled in a variety ofconfigurations, in particular by gluing or heat embossing, for example.

The absorbent core 228 may comprise an absorbent material comprising atleast 80% by weight, at least 85% by weight, at least 90% by weight, atleast 95% by weight, or at least 99% by weight of superabsorbentpolymers, and a core wrap enclosing the superabsorbent polymers. Thecore wrap may typically comprise two materials, substrates, or nonwovenmaterials 216 and 216′ for the top side and the bottom side of the core.These types of cores are known as airfelt-free cores. The core maycomprise one or more channels, represented in FIG. 28 as the fourchannels 226, 226′ and 227, 227′. The channels 226, 226′, 227, and 227′are optional features. Instead, the core may not have any channels ormay have any number of channels.

These and other components of the example absorbent articles will now bediscussed in more details.

Topsheet

In the present disclosure, the topsheet (the portion of the absorbentarticle that contacts the wearer's skin and receives the fluids) may beformed of a portion of, or all of, one or more of the three-dimensionalnonwoven materials described herein and/or have one or more of thenonwoven materials positioned thereon and/or joined thereto, so that thenonwoven material(s) contact(s) the wearer's skin. Other portions of thetopsheet (other than the three-dimensional nonwoven materials) may alsocontact the wearer's skin. The three-dimensional nonwoven materials maybe positioned as a strip or a patch on top of the typical topsheet 224.Alternatively, the three-dimensional nonwoven material may only form acentral CD area of the topsheet. The central CD area may extend the fullMD length of the topsheet or less than the full MD length of thetopsheet.

The topsheet 224 may be joined to the backsheet 225, the absorbent core228 and/or any other layers as is known to those of skill in the an.Usually, the topsheet 224 and the backsheet 225 are joined directly toeach other in some locations (e.g., on or close to the periphery of theabsorbent article) and are indirectly joined together in other locationsby directly joining them to one or more other elements of the article220.

The topsheet 224 may be compliant, soft-feeling, and non-irritating tothe wearer's skin. Further, a portion of, or all of, the topsheet 224may be liquid permeable, permitting liquids to readily penetrate throughits thickness. Furthermore, a portion of, or all of, the topsheet 224may be treated with surfactants or other agents to either hydrophilizethe web or make it hydrophobic. Any portion of the topsheet 224 may becoated with a lotion and/or a skin care composition as is generallydisclosed in the art. The topsheet 224 may also comprise or be treatedwith antibacterial agents.

Backsheet

The backsheet 225 is generally that portion of the absorbent article 220positioned adjacent the garment-facing surface of the absorbent core 228and which prevents, or at least inhibits, the fluids and bodily exudatesabsorbed and contained therein from soiling articles such as bedsheetsand undergarments. The backsheet 225 is typically impermeable, or atleast substantially impermeable, to fluids (e.g., urine). The backsheetmay, for example, be or comprise a thin plastic film such as athermoplastic film having a thickness of about 0.012 mm to about 0.051mm. Other suitable backsheet materials may include breathable materialswhich permit vapors to escape from the absorbent article 220, whilestill preventing, or at least inhibiting, fluids from passing throughthe backsheet 225.

The backsheet 225 may be joined to the topsheet 224, the absorbent core228, and/or any other element of the absorbent article 220 by anyattachment methods known to those of skill in the art.

The absorbent article may comprise a backsheet comprising an outer coveror an outer cover nonwoven. An outer cover or outer cover nonwoven ofthe absorbent article 220 may cover at least a portion of, or all of,the backsheet 225 to form a soft garment-facing surface of the absorbentarticle. The outer cover or outer cover nonwoven may be formed of thehigh loft, three-dimensional nonwoven materials described herein.Alternatively, the outer cover or outer cover nonwoven may comprise oneor more known outer cover materials. If the outer cover comprises one ofthe three-dimensional nonwoven materials of the present disclosure, thethree-dimensional nonwoven material of the outer cover may or may notmatch (e.g., same material, same pattern) a three-dimensional nonwovenmaterial used as the topsheet or the topsheet and the acquisition layerof the absorbent article. In other instances, the outer cover may have aprinted or otherwise applied pattern that matches or visually resemblesthe pattern of the three-dimensional nonwoven materials used as thetopsheet or the topsheet and the acquisition layer laminate of theabsorbent article. The outer cover may be joined to at least a portionof the backsheet 225 through mechanical bonding, ultrasonic, thermalbonding, adhesive bonding, or other suitable methods of attachment.

Absorbent Core

The absorbent core is the component of the absorbent article that hasthe most absorbent capacity and that comprises an absorbent material anda core wrap or core bag enclosing the absorbent material. The absorbentcore does not include the acquisition and/or distribution system or anyother components of the absorbent article which are not either integralpart of the core wrap or core bag or placed within the core wrap or corebag. The absorbent core may comprise, consist essentially of, or consistof, a core wrap, an absorbent material (e.g., superabsorbent polymersand little or no cellulose fibers) as discussed, and glue.

The absorbent core 228 may comprise an absorbent material with a highamount of superabsorbent polymers (herein abbreviated as “SAP”) enclosedwithin the core wrap. The SAP content may represent 70%-100% or at least70%, 75%, 80%, 85%, 90%, 95%, 99%, or 100%, by weight of the absorbentmaterial, contained in the core wrap. The core wrap is not considered asabsorbent material for the purpose of assessing the percentage of SAP inthe absorbent core. The absorbent core may contain airfelt with orwithout superabsorbent polymers.

By “absorbent material” it is meant a material which has some absorbencyproperty or liquid retaining properties, such as SAP, cellulosic fibersas well as synthetic fibers. Typically, glues used in making absorbentcores have no or little absorbency properties and are not considered asabsorbent material. The SAP content may be higher than 80%, for exampleat least 85%, at least 90%, at least 95%, at least 99%, and even up toand including 100% of the weight of the absorbent material containedwithin the core wrap. This airfelt-free core is relatively thin comparedto a conventional core typically comprising between 40-60% SAP by weightand a high content of cellulose fibers. The absorbent material may inparticular comprises less than 15% weight percent or less than 10%weight percent of natural, cellulosic, or synthetic fibers, less than 5%weight percent, less than 3% weight percent, less than 2% weightpercent, less than 1% weight percent, or may even be substantially freeof natural, cellulosic, and/or synthetic fibers.

As referenced above, the airfelt-free cores with very little or nonatural, cellulosic and/or synthetic fibers are quite thin compared toconventional cores, thereby making the overall absorbent article thinnerthan absorbent articles with cores comprising mixed SAP and cellulosicfibers (e.g., 40-60% cellulose fibers). This core thinness can lead toconsumer perceptions of reduced absorbency and performance, althoughtechnically this is not the case. Presently, these thin cores havetypically been used with substantially planer or apertured topsheets.Furthermore, absorbent articles having these thin airfelt-free coreshave reduced capillary void space since there is little or no natural,cellulosic, or synthetic fibers in the cores. Thus, there may sometimesnot be enough capillary void space in the absorbent article to fullyaccept multiple insults of bodily exudates or a single large insult.

To solve such problems, the present disclosure provides absorbentarticles with these thin airfelt-free cores in combination with one ofthe high-loft, three-dimensional nonwoven materials described herein asa topsheet or as a topsheet and acquisition layer laminate. In such aninstance, consumer perception of absorbency and performance, through theincreased thickness of the absorbent article owing to the additionalthickness provided by the high-loft, three-dimensional nonwovenmaterial, is increased. Furthermore, the three-dimensional nonwovenmaterials, when used with these thin airfelt-free cores and as thetopsheet or the topsheet and acquisition layer laminate, add capillaryvoid space back into the absorbent articles, while still allowing forminimal stack heights, thereby passing cost savings onto consumers andmanufactures. As such, the absorbent articles of the present disclosuremay easily absorb multiple bodily exudate insults or single largeinsults owing to this increased capillary void space. Additionally,absorbent articles that comprise the nonwoven materials as the topsheetor the topsheet and acquisition layer laminate provide consumers with anaesthetically pleasing topsheet relative to a planer topsheet or anapertured topsheet with an increased thickness and thus the consumerperceptions of absorbency and performance.

The example absorbent core 228 of the absorbent article 220 of FIGS.31-32 is shown in isolation in FIGS. 33-35 . The absorbent core 228 maycomprises a front side 480, a rear side 282, and two longitudinal sides284, 286 joining the front side 480 and the rear side 282. The absorbentcore 228 may also comprise a generally planar top side and a generallyplanar bottom side. The front side 480 of the core is the side of thecore intended to be placed towards the front waist edge 210 of theabsorbent article. The core 228 may have a longitudinal axis 280′corresponding substantially to the longitudinal axis 280 of theabsorbent article 220, as seen from the top in a planar view as in FIG.28 . The absorbent material may be distributed in higher amount towardsthe front side 480 than towards the rear side 282 as more absorbency maybe required at the front in particular absorbent articles. The front andrear sides 480 and 282 of the core may be shorter than the longitudinalsides 284 and 286 of the core. The core wrap may be formed by twononwoven materials, substrates, laminates, or other materials, 216, 216′which may be at least partially sealed along the sides 284, 286 of theabsorbent core 228. The core wrap may be at least partially sealed alongits front side 480, rear side 282, and two longitudinal sides 284, 286so that substantially no absorbent material leaks out of the absorbentcore wrap. The first material, substrate, or nonwoven 216 may at leastpartially surround the second material, substrate, or nonwoven 216′ toform the core wrap, as illustrated in FIG. 34 . The first material 216may surround a portion of the second material 216′ proximate to thefirst and second side edges 284 and 286.

The absorbent core may comprise adhesive, for example, to helpimmobilizing the SAP within the core wrap and/or to ensure integrity ofthe core wrap, in particular when the core wrap is made of two or moresubstrates. The adhesive may be a hot melt adhesive, supplied, by H. B.Fuller, for example. The core wrap may extend to a larger area thanstrictly needed for containing the absorbent material within.

The absorbent material may be a continuous layer present within the corewrap. Alternatively, the absorbent material may be comprised ofindividual pockets or stripes of absorbent material enclosed within thecore wrap. In the first case, the absorbent material may be, forexample, obtained by the application of a single continuous layer ofabsorbent material. The continuous layer of absorbent material, inparticular of SAP, may also be obtained by combining two absorbentlayers having discontinuous absorbent material application patterns,wherein the resulting layer is substantially continuously distributedacross the absorbent particulate polymer material area, as disclosed inU.S. Pat. Appl. Pub. No. 2008/0312622A1 (Hundorf), for example. Theabsorbent core 228 may comprise a first absorbent layer and a secondabsorbent layer. The first absorbent layer may comprise the firstmaterial 216 and a first layer 261 of absorbent material, which may be100% or less of SAP. The second absorbent layer may comprise the secondmaterial 216′ and a second layer 262 of absorbent material, which mayalso be 100% or less of SAP. The absorbent core 228 may also comprise afibrous thermoplastic adhesive material 251 at least partially bondingeach layer of absorbent material 261, 262 to its respective material 216or 216′. This is illustrated in FIGS. 34-35 , as an example, where thefirst and second SAP layers have been applied as transversal stripes or“land areas” having the same width as the desired absorbent materialdeposition area on their respective substrate before being combined. Thestripes may comprise different amounts of absorbent material (SAP) toprovide a profiled basis weight along the longitudinal axis of the core280. The first material 216 and the second material 216′ may form thecore wrap.

The fibrous thermoplastic adhesive material 251 may be at leastpartially in contact with the absorbent material 261, 262 in the landareas and at least partially in contact with the materials 216 and 216′in the junction areas. This imparts an essentially three-dimensionalstructure to the fibrous layer of thermoplastic adhesive material 251,which in itself is essentially a two-dimensional structure of relativelysmall thickness, as compared to the dimension in length and widthdirections. Thereby, the fibrous thermoplastic adhesive material mayprovide cavities to cover the absorbent material in the land areas, andthereby immobilizes this absorbent material, which may be 100% or lessof SAP.

The thermoplastic adhesive used for the fibrous layer may haveelastomeric properties, such that the web formed by the fibers on theSAP layer is able to be stretched as the SAP swell.

Superabsorbent Polymer (SAP)

The SAP useful with the present disclosure may include a variety ofwater-insoluble, but water-swellable polymers capable of absorbing largequantities of fluids.

The superabsorbent polymer may be in particulate form so as to beflowable in the dry state. Particulate absorbent polymer materials maybe made of poly(meth)acrylic acid polymers. However, starch-basedparticulate absorbent polymer material may also be used, as well aspolyacrylamide copolymer, ethylene maleic anhydride copolymer,cross-linked carboxymethylcellulose, polyvinyl alcohol copolymers,cross-linked polyethylene oxide, and starch grafted copolymer ofpolyacrylonitrile.

The SAP may be of numerous shapes. The term “particles” refers togranules, fibers, flakes, spheres, powders, platelets and other shapesand forms known to persons skilled in the art of superabsorbent polymerparticles. The SAP particles may be in the shape of fibers, i.e.,elongated, acicular superabsorbent polymer particles. The fibers mayalso be in the form of a long filament that may be woven. SAP may bespherical-like particles. The absorbent core may comprise one or moretypes of SAP.

For most absorbent articles, liquid discharges from a wearer occurpredominately in the front half of the absorbent article, in particularfor a diaper. The front half of the article (as defined by the regionbetween the front edge and a transversal line placed at a distance ofhalf L from the front waist edge 210 or rear waist edge 212 maytherefore may comprise most of the absorbent capacity of the core. Thus,at least 60% of the SAP, or at least 65%, 70%, 75%, 80%, or 85% of theSAP may be present in the front half of the absorbent article, while theremaining SAP may be disposed in the rear half of the absorbent article.Alternatively, the SAP distribution may be uniform through the core ormay have other suitable distributions.

The total amount of SAP present in the absorbent core may also varyaccording to expected user. Diapers for newborns may require less SAPthan infant, child, or adult incontinence diapers. The amount of SAP inthe core may be about 5 to 60 g or from 5 to 50 g. The average SAP basisweight within the (or “at least one”, if several are present) depositionarea 8 of the SAP may be at least 50, 100, 200, 300, 400, 500 or moreg/m². The areas of the channels (e.g., 226, 226′, 227, 227′) present inthe absorbent material deposition area 8 are deduced from the absorbentmaterial deposition area to calculate this average basis weight.

Core Wrap

The core wrap may be made of a single substrate, material, or nonwovenfolded around the absorbent material, or may comprise two (or more)substrates, materials, or nonwovens which are attached to another.Typical attachments are the so-called C-wrap and/or sandwich wrap. In aC-wrap, as illustrated, for example, in FIGS. 29 and 34 , thelongitudinal and/or transversal edges of one of the substrates arefolded over the other substrate to form flaps. These flaps are thenbonded to the external surface of the other substrate, typically bygluing.

The core wrap may be formed by any materials suitable for receiving andcontaining the absorbent material. Typical substrate materials used inthe production of conventional cores may be used, in particular paper,tissues, films, wovens or nonwovens, or laminates or composites of anyof these.

The substrates may also be air-permeable (in addition to being liquid orfluid permeable). Films useful herein may therefore comprisemicro-pores.

The core wrap may be at least partially sealed along all the sides ofthe absorbent core so that substantially no absorbent material leaks outof the core. By “substantially no absorbent material” it is meant thatless than 5%, less than 2%, less than 1%, or about 0% by weight ofabsorbent material escape the core wrap. The term “seal” is to beunderstood in a broad sense. The seal does not need to be continuousalong the whole periphery of the core wrap but may be discontinuousalong part or the whole of it, such as formed by a series of seal pointsspaced on a line. A seal may be formed by gluing and/or thermal bonding.

If the core wrap is formed by two substrates 216, 216′, four seals maybe used to enclose the absorbent material 260 within the core wrap. Forexample, a first substrate 216 may be placed on one side of the core(the top side as represented in FIGS. 33-35 ) and extend around thecore's longitudinal edges to at least partially wrap the opposed bottomside of the core. The second substrate 216′ may be present between thewrapped flaps of the first substrate 216 and the absorbent material 260.The flaps of the first substrate 216 may be glued to the secondsubstrate 216′ to provide a strong seal. This so called C-wrapconstruction may provide benefits such as improved resistance tobursting in a wet loaded state compared to a sandwich seal. The frontside and rear side of the core wrap may then also be sealed by gluingthe first substrate and second substrate to another to provide completeencapsulation of the absorbent material across the whole of theperiphery of the core. For the front side and rear side of the core, thefirst and second substrates may extend and may be joined together in asubstantially planar direction, forming for these edges a so-calledsandwich construction. In the so-called sandwich construction, the firstand second substrates may also extend outwardly on all sides of the coreand be sealed flat, or substantially flat, along the whole or parts ofthe periphery of the core typically by gluing and/or heat/pressurebonding. In an example, neither the first nor the second substrates needto be shaped, so that they may be rectangularly cut for ease ofproduction but other shapes are also within the scope of the presentdisclosure.

The core wrap may also be formed by a single substrate which may encloseas in a parcel wrap the absorbent material and be sealed along the frontside and rear side of the core and one longitudinal seal.

SAP Deposition Area

The absorbent material deposition area 208 may be defined by theperiphery of the layer formed by the absorbent material 260 within thecore wrap, as seen from the top side of the absorbent core. Theabsorbent material deposition area 208 may have various shapes, inparticular, a so-called “dog bone” or “hour-glass” shape, which shows atapering along its width towards the middle or “crotch” region of thecore. In this way, the absorbent material deposition area 8 may have arelatively narrow width in an area of the core intended to be placed inthe crotch region of the absorbent article, as illustrated in FIG. 28 .This may provide better wearing comfort. The absorbent materialdeposition area 8 may also be generally rectangular, for example asshown in FIGS. 31-33 , but other deposition areas, such as arectangular, “T,” “Y,” “sand-hour,” or “dog-bone” shapes are also withinthe scope of the present disclosure. The absorbent material may bedeposited using any suitable techniques, which may allow relativelyprecise deposition of SAP at relatively high speed.

Channels

The absorbent material deposition area 208 may comprise at least onechannel 226, which is at least partially oriented in the longitudinaldirection of the article 280 (i.e., has a longitudinal vector component)as shown in FIGS. 28 and 29 . Other channels may be at least partiallyoriented in the lateral direction (i.e., has a lateral vector component)or in any other direction. In the following, the plural form “channels”will be used to mean “at least one channel”. The channels may have alength L′ projected on the longitudinal axis 280 of the article that isat least 10% of the length L of the article. The channels may be formedin various ways. For example, the channels may be formed by zones withinthe absorbent material deposition area 208 which may be substantiallyfree of, or free of, absorbent material, in particular SAP. In anotherexample, the channels may be formed by zones within the absorbentmaterial deposition area 208 where the absorbent material of the corecomprises cellulose, airfelt, SAP, or combinations thereof and thechannels may be substantially free of, or free of, absorbent material,in particular the SAP, cellulose, or airfelt In addition oralternatively, the channel(s) may also be formed by continuously ordiscontinuously bonding the top side of the core wrap to the bottom sideof the core wrap through the absorbent material deposition area 208. Thechannels may be continuous, but it is also envisioned that the channelsmay be intermittent. The acquisition-distribution system or layer 250,or another layer of the article, may also comprise channels, which mayor not correspond to the channels of the absorbent core.

In some instances, the channels may be present at least at the samelongitudinal level as the crotch point C or the lateral axis 260 in theabsorbent article, as represented in FIG. 28 with the two longitudinallyextending channels 226, 226′. The channels may also extend from thecrotch region 207 or may be present in the front waist region 205 and/orin the rear waist region 206 of the article.

The absorbent core 228 may also comprise more than two channels, forexample, at least 3, at least 4, at least 5, or at least 6 or more.Shorter channels may also be present, for example in the rear waistregion 206 or the front waist region 205 of the core as represented bythe pair of channels 227, 227′ in FIG. 28 towards the front of thearticle. The channels may comprise one or more pairs of channelssymmetrically arranged, or otherwise arranged relative to thelongitudinal axis 280.

The channels may be particularly useful in the absorbent core when theabsorbent material deposition area is rectangular, as the channels mayimprove the flexibility of the core to an extent that there is lessadvantage in using a non-rectangular (shaped) core. Of course channelsmay also be present in a layer of SAP having a shaped deposition area.

The channels may be completely oriented longitudinally and parallel tothe longitudinal axis or completely oriented transversely and parallelto the lateral axis, but also may have at least portions that arecurved.

In order to reduce the risk of fluid leakages, the longitudinal mainchannels may not extend up to any of the edges of the absorbent materialdeposition area 208, and may therefore be fully encompassed within theabsorbent material deposition area 208 of the core. The smallestdistance between a channel and the closest edge of the absorbentmaterial deposition area 208 may be at least 5 mm.

The channels may have a width We along at least part of their lengthwhich is at least 2 mm, at least 3 mm, at least 4 mm, up to for example20 mm, 16 mm, or 12 mm, for example. The width of the channel(s) may beconstant through substantially the whole length of the channel or mayvary along its length. When the channels are formed by absorbentmaterial-free zone within the absorbent material deposition area 208,the width of the channels is considered to be the width of the materialfree zone, disregarding the possible presence of the core wrap withinthe channels. If the channels are not formed by absorbent material freezones, for example mainly though bonding of the core wrap through theabsorbent material zone, the width of the channels is the width of thisbonding.

At least some or all of the channels may be permanent channels, meaningtheir integrity is at least partially maintained both in the dry stateand in the wet state. Permanent channels may be obtained by provision ofone or more adhesive materials, for example, the fibrous layer ofadhesive material or construction glue that helps adhere a substratewith an absorbent material within the walls of the channel. Permanentchannels may also be formed by bonding the upper side and lower side ofthe core wrap (e.g., the first substrate 216 and the second substrate216′) and/or the topsheet 224 to the backsheet 225 together through thechannels. Typically, an adhesive may be used to bond both sides of thecore wrap or the topsheet and the backsheet through the channels, but itis possible to bond via other known processes, such as pressure bonding,ultrasonic bonding, heat bonding, or combination thereof. The core wrapor the topsheet 224 and the backsheet 225 may be continuously bonded orintermittently bonded along the channels. The channels mayadvantageously remain or become visible at least through the topsheetand/or backsheet when the absorbent article is fully loaded with afluid. This may be obtained by making the channels substantially free ofSAP, so they will not swell, and sufficiently large so that they willnot close when wet. Furthermore, bonding the core wrap to itself or thetopsheet to the backsheet through the channels may be advantageous.

Barrier Leg Cuffs

The absorbent article may comprise a pair of barrier leg cuffs 34. Eachbarrier leg cuff may be formed by a piece of material which is bonded tothe absorbent article so it may extend upwards from a wearer-facingsurface of the absorbent article and provide improved containment offluids and other body exudates approximately at the junction of thetorso and legs of the wearer. The barrier leg cuffs are delimited by aproximal edge 64 joined directly or indirectly to the topsheet 224and/or the backsheet 225 and a free terminal edge 266, which is intendedto contact and form a seal with the wearer's skin. The barrier leg cuffs234 extend at least partially between the front waist edge 210 and therear waist edge 212 of the absorbent article on opposite sides of thelongitudinal axis 280 and are at least present at the level of thecrotch point (C) or crotch region. The barrier leg cuffs may be joinedat the proximal edge 264 with the chassis of the article by a bond 265which may be made by gluing, fusion bonding, or a combination of othersuitable bonding processes. The bond 265 at the proximal edge 264 may becontinuous or intermittent. The bond 265 closest to the raised sectionof the leg cuffs delimits the proximal edge 264 of the standing upsection of the leg cuffs.

The barrier leg cuffs may be integral with the topsheet 224 or thebacksheet 225 or may be a separate material joined to the article'schassis. Each barrier leg cuff 234 may comprise one, two or more elasticstrings 235 close to the free terminal edge 266 to provide a betterseal.

In addition to the barrier leg cuffs 234, the article may comprisegasketing cuffs 232, which are joined to the chassis of the absorbentarticle, in particular to the topsheet 224 and/or the backsheet 225 andare placed externally relative to the barrier leg cuffs. The gasketingcuffs 232 may provide a better seal around the thighs of the wearer.Each gasketing leg cuff may comprise one or more elastic strings orelastic elements 233 in the chassis of the absorbent article between thetopsheet 224 and backsheet 225 in the area of the leg openings. All, ora portion of, the barrier leg cuffs and/or gasketing cuffs may betreated with a lotion or another skin care composition.

Acquisition-Distribution System

The absorbent articles of the present disclosure may comprise anacquisition-distribution layer or system 250 (“ADS”). One function ofthe ADS is to quickly acquire one or more of the fluids and distributethem to the absorbent core in an efficient manner. The ADS may compriseone, two or more layers, which may form a unitary layer or may remain asdiscrete layers which may be attached to each other. In an example, theADS may comprise two layers: a distribution layer 254 and an acquisitionlayer 252 disposed between the absorbent core and the topsheet, but thepresent disclosure is not so limited.

In one example, the high loft, three-dimensional nonwoven materials ofthe present disclosure may comprise the topsheet and the acquisitionlayer as a laminate. A distribution layer may also be provided on thegarment-facing side of the topsheet/acquisition layer laminate.

Carrier Layer

In an instance where the high loft, three-dimensional nonwoven materialsof the present disclosure encompass a topsheet and acquisition layerlaminate, the distribution layer may need to be supported by a carrierlayer (not illustrated) that may comprise one or more nonwoven materialsor other materials. The distribution layer may be applied to orpositioned on the carrier layer. As such, the carrier layer may bepositioned intermediate the acquisition layer and the distribution layerand be in a facing relationship with the acquisition layer and thedistribution layer.

Distribution Layer

The distribution layer of the ADS may comprise at least 50% by weight ofcross-linked cellulose fibers. The cross-linked cellulosic fibers may becrimped, twisted, or curled, or a combination thereof including crimped,twisted, and curled. This type of material is disclosed in U.S. Pat.Publ. No. 2008/0312622 A1 (Hundorf). The cross-linked cellulosic fibersprovide higher resilience and therefore higher resistance to the firstabsorbent layer against the compression in the product packaging or inuse conditions. e.g., under wearer weight. This may provide the corewith a higher void volume, permeability, and liquid absorption, andhence reduced leakage and improved dryness.

The distribution layer comprising the cross-linked cellulose fibers ofthe present disclosure may comprise other fibers, but this layer mayadvantageously comprise at least 50%, or 60%, or 70%, or 80%, or 90%, oreven up to 100%, by weight of the layer, of cross-linked cellulosefibers (including the cross-linking agents).

Acquisition Layer

If a three-dimensional nonwoven material of the present disclosure isprovided as only the topsheet of an absorbent article, the ADS 250 maycomprise an acquisition layer 252. The acquisition layer may be disposedbetween the distribution layer 254 and the topsheet 224. In such aninstance, the acquisition layer 252 may be or may comprise a nonwovenmaterial, such as a hydrophilic SMS or SMMS material, comprising aspunbonded, a melt-blown and a further spunbonded layer or alternativelya carded staple fiber chemical-bonded nonwoven. The nonwoven materialmay be latex bonded.

Fastening System

The absorbent article may comprise a fastening system. The fasteningsystem may be used to provide lateral tensions about the circumferenceof the absorbent article to hold the absorbent article on the wearer asis typical for taped diapers. This fastening system may not be necessaryfor training pant articles since the waist region of these articles isalready bonded. The fastening system may comprise a fastener such astape tabs, hook and loop fastening components, interlocking fastenerssuch as tabs & slots, buckles, buttons, snaps, and/or hermaphroditicfastening components, although any other suitable fastening mechanismsare also within the scope of the present disclosure. A landing zone 244is normally provided on the garment-facing surface of the front waistregion 205 for the fastener to be releasably attached thereto.

Front and Rear Ears

The absorbent article may comprise front ears 246 and rear ears 240. Theears may be an integral part of the chassis, such as formed from thetopsheet 224 and/or backsheet 226 as side panels. Alternatively, asrepresented on FIG. 28 , the ears may be separate elements attached bygluing, heat embossing, and/or pressure bonding. The rear ears 240 maybe stretchable to facilitate the attachment of the tabs 242 to thelanding zone 244 and maintain the taped diapers in place around thewearer's waist. The rear ears 240 may also be elastic or extensible toprovide a more comfortable and contouring fit by initially conformablyfitting the absorbent article to the wearer and sustaining this fitthroughout the time of wear well past when absorbent article has beenloaded with fluids or other bodily exudates since the elasticized earsallow the sides of the absorbent article to expand and contract.

Elastic Waist Feature

The absorbent article 220 may also comprise at least one elastic waistfeature (not represented) that helps to provide improved fit andcontainment. The elastic waist feature is generally intended toelastically expand and contract to dynamically fit the wearer's waist.The elastic waist feature may extend at least longitudinally outwardlyfrom at least one waist edge of the absorbent core 228 and generallyforms at least a portion of the end edge of the absorbent article.Disposable diapers may be constructed so as to have two elastic waistfeatures, one positioned in the front waist region and one positioned inthe rear waist region.

Color Signals

In a form, the absorbent articles of the present disclosure may havedifferent colors in different layers, or portions thereof (e.g., thetopsheet and the acquisition layer, the topsheet and the nonwoven corecover, a first portion and a second portion of a topsheet, a firstportion and second portion of the acquisition layer). The differentcolors may be shade of the same color (e.g., dark blue and light blue)or may be actual different colors (e.g., purple and green). Thedifferent colors may have a Delta E in the range of about 1.5 to about10, about 2 to about 8, or about 2 to about 6, for example. Other DeltaE ranges are also within the scope of the present disclosure.

In an instance, various layers of the absorbent articles may be joinedusing a colored adhesive. The colored adhesive may be laid down on anysuitable layer or layers in a pattern. The pattern of the adhesive mayor may not complement the pattern of the topsheet. Such a pattern mayincrease the appearance of depth in an absorbent article. In certaininstances, the colored adhesive may be blue.

In other instances, any of the layers may comprise indicia, such as aprinted ink to aid in the appearance, depth impression, absorbencyimpression, or quality impression of the absorbent articles.

In other instances, the colors may be complimentary, or registered with,the patterns of three-dimensional features of the nonwoven fabric 10utilized as a component in an absorbent article. For example, a fabrichaving first and second zones of visually distinct patterns ofthree-dimensional features may also have printed thereon color toemphasize, highlight, contrast with, or otherwise change the visualappearance of the fabric 10. The color enhancements can be beneficial incommunicating to a user of an absorbent article certain functionalcharacteristics of the nonwoven fabric 10 when in use. Thus color can beused in combination with structural, three-dimensional features in onecomponent, or in combinations of components to deliver a visuallydistinctive absorbent article. For example, a secondary topsheet oracquisition layer may have printed thereon a pattern of color or colorsthat compliments the pattern of three-dimensional features of a fabric10 utilized as a topsheet in an absorbent article. Another example is anabsorbent article comprising 1) an absorbent core comprising a channel,2) a topsheet with a three dimensional pattern registered orhighlighting the channel or channels in the core, and 3) a graphic,colored component, printed ink, or indicia visible from the topsheetviewing (body contacting surface) or the backsheet viewing surface(garment facing surface) to further emphasize the functional features ofthe core channel or channels and the overall performance of theabsorbent article.

Further characterization of the novel aspects of the present disclosurecan be realized by focusing on the three-dimensional features within avisually discernible zone. Each zone, such as Zones 110, 120, and 130,discussed above, can be described further with respect to microzones. Amicrozone is a portion of the nonwoven fabric 10 within a zone, that hasat least two visually discernible regions and there is a commonintensive property difference between these two regions. A microzone maycomprise a portion of the nonwoven fabric 10 which crosses two or morezone boundaries that has at least two visually discernible regions andthere is a common intensive property difference between these tworegions

The benefit of considering microzones in the present disclosure is toillustrate that in addition to differences in average intensiveproperties with a zone, such as zones 110, 120, and 130, as discussedabove, the present disclosure also provides for fabrics havingdifferences in actual and/or average intensive properties betweenregions defined by the three-dimensional features within a zone, withthe three-dimensional features precisely placed according to the designof the forming belt used to produce the fabrics. The difference betweenintensive properties between regions of the three-dimensional featuresprovides for additional visual as well as functional benefits. The sharpvisual contrast between regions can provide for extremely fine visuallydistinctive designs within a zone and between zones. Likewise, theprecise placement of regions afforded by the precisely manufacturedforming belt can provide for excellent and tailored softness, strength,and fluid handling properties of the zones. Thus, the invention in oneembodiment provides for the unexpected combination of differences inaverage intensive properties between zones and simultaneouslydifferences in intensive properties of the regions making up amicrozone.

Regions defined by three-dimensional features can be understood withreference to FIG. 38 and FIG. 39 . FIG. 38 shows a light microscopeimage of a portion of a fabric 10 according to the present disclosure,and FIG. 39 is a scanning electron micrograph (SEM) of a cross-sectionof the portion of the fabric shown in FIG. 38 . Thus. FIGS. 38 and 39show a portion of a nonwoven fabric 10 magnified for more precisedescription of the otherwise visually discernible features of thefabric. The portion of the nonwoven fabric 10 shown in FIG. 38 isapproximately 36 mm in the CD and exhibits portions of at least threevisually distinct zones as discussed below.

In FIGS. 38 and 39 which show a portion of one pattern of a nonwovenfabric 10, a first zone 110 (on the left side of FIG. 38 ) ischaracterized by generally MD-oriented rows of variable width firstregions 300 separated by MD-oriented rows of variable width secondregions 310. The first region is also the three-dimensional feature 20that defines the first and second regions 300, 310. In an embodiment, athree-dimensional feature is a portion of the nonwoven fabric 10 thatwas formed between or around a raised element of the forming belt, whichin this description is the first region 300, such that the resultingstructure has a relatively greater dimension in the Z-direction. Theadjacent second region 310 generally has a common intensive propertywith first region 300, and in an embodiment has relatively lowerthickness values, i.e., lesser dimension in the Z-direction. Therelative dimensions in the Z direction with respect to a plane of thefirst surface 16 as described above, can be seen in FIG. 39 . Absolutedimensions are not critical; but the dimensional differences can bevisually discernible on the nonwoven fabric 10 without magnification.

The invention of the disclosure permits beneficial characteristics bestexpressed with respect to the regions defined by three-dimensionalfeatures in microzones. For example, as shown in FIG. 38 , in zone 110for each three dimensional features 20 there is a visible distinctionbetween a first region 300 and a second region 310. As stated above, thevisible distinction can exist in the nonwoven fabric 10 withoutmagnification; the magnified views used herein are for purposes of cleardisclosure. Any area that extends across the boundary between enough offirst region 300 and second region 310 such that a difference in theirrespective intensive properties can be ascertained within the area canbe a microzone. Additionally, light microscopy or microCT imagery of astructure can also be used to establish the location of regions and thearea of a microzone.

The portion of nonwoven fabric 10 shown in FIG. 38 further illustratesanother beneficial characteristic of the fabric 10, in that thedifferences in intensive properties between adjacent regions can bedifferences across zones. Thus, a microzone that spans an areaencompassing second region 310 of zone 120 and first region 300 of zone130 can be identified. In certain embodiments, including in the nonwovenfabric 10 shown in FIGS. 38 and 39 , the difference in intensiveproperties exhibited by regions in microzones that a zone boundary canbe significantly different in magnitude than the differences betweenintensive properties exhibited by regions within a zone.

Regardless of which zone, or which zonal boundary a particular microzoneencompasses, the three-dimensional features can be characterized by thedifferences between intensive properties of the regions defined by them.In general, the nonwoven of the present disclosure can be a spunbondnonwoven fabric having a first surface defining a plane of the firstsurface. The fabric can have a plurality of three-dimensional features,each three dimensional feature defining a first region and a secondregion, the regions having a common intensive property that has adifferent value between them. In an embodiment, the first region can bedistinguished as being at a higher elevation than the second region withrespect to the plane of the first surface, hence exhibiting a differencein each region's common intensive property of thickness. The two regionscan also be distinguished as having different densities, basis weights,and volumetric densities. That is, the two regions can be distinguishedwithin a micro zone of the spunbond nonwoven fabric as being differentwith respect to common intensive properties, including properties suchas thickness, density, basis weight, and volumetric density. In anembodiment one or both regions of a microzone can be fluid permeable. Inan embodiment, the higher density region of a microzone can be fluidpermeable.

Within zone 110 of the portion of fabric shown in FIG. 38 , for example,there can be three-dimensional features 20 defining at least tworegions, a first region 300 and a second region 310. The difference inthickness, basis weight, and volumetric density between the first andsecond regions for zone 110 shown in FIG. 38 can be 274 microns, 1 gsm,and 0.437 g/cc, respectively.

Likewise, within zone 130 of the portion of fabric shown in FIG. 38 ,for example, there can be three-dimensional features 20 defining atleast two regions, a first region 300 and a second region 310. Thedifference in thickness, basis weight, and volumetric density betweenthe first and second regions for zone 130 shown in FIG. 38 can be 2083microns, 116 gsm, and 0.462 g/cc, respectively.

Additionally, within zone 120 of the portion of fabric shown in FIG. 38, for example, there can be three-dimensional features 20 defining atleast two regions, a first region 300 and a second region 310. Thedifference in thickness, basis weight, volumetric density between thefirst and second regions for the portion of fabric shown in FIG. 38 canbe 204 microns, 20 gsm, 0.53 g/cc, respectively. In the embodimentshown, zone 120 forms what appears in an unmagnified view of nonwovenfabric 10 to be a stitched boundary between zones 110 and 130.

Further, a zone that encompasses the boundary between zones 120 and 130of the portion of fabric shown in FIG. 38 , for example, there are atleast two regions, a first region 300 in zone 130 and a second region310 in zone 120. The difference in thickness, basis weight, andvolumetric density between the first and second regions for the portionof fabric shown in FIG. 38 can be 2027 microns, 58 gsm, and 0.525 g/cc,respectively.

Microzones are discussed in more detail with reference to FIGS. 40-42and the data depicted in FIG. 44 . FIGS. 40-42 are Micro-CT scans of aportion of a nonwoven fabric 10 similar in pattern to that of thenonwoven fabric 10 shown in FIG. 38 . The Micro-CT scan permitsdescription of the same features as shown in FIG. 38 in a slightlydifferent manner and in a way that permits very precise measurement ofintensive properties.

As shown in FIG. 40 , zones 110, 120, and 130 are clearly visible, withtheir respective three-dimensional features 20. As depicted in FIGS. 40and 41 , the three-dimensional features are the dark-colored portions,with the dark color also representing the first region 300 of athree-dimensional feature 20, and the adjacent light-colored portionsbeing the second region 310 for the three-dimensional feature 20.

The Micro-CT scan permits the image to be “cut” and cross-sectioned, asshown by the cut plane 450 in FIG. 41 . A cut plane can be placedanywhere on the image; for the purposes of the present disclosure, thecut plane 450 cuts a cross section substantially parallel to the Z axisso as to produce the cross-sectional image in FIG. 42 .

The Micro-CT technology permits intensive properties to be precisely anddirectly measured. Thickness measurements can be made directly fromimaged cross sections based on the scale magnification, such as thecross section shown in FIG. 42 . Further, the color differential betweenfirst regions and second regions is representative and proportional todifferences in basis weight, volumetric density, and other intensiveproperties, which can likewise be directly measured. Micro-CTmethodology is explained below in the Test Methods section.

FIG. 43 is a Micro-CT scan image of the portion of nonwoven fabric 10shown in FIGS. 40 and 41 . Utilizing, for specific first and secondregions shown as numbered portions of the nonwoven fabric 10 can beanalyzed. In FIG. 43 , specific regions were manually selected andanalyzed to measure thickness, basis weight, and volumetric density, andthe data is produced in FIG. 44 .

FIG. 44 shows data for groupings of first and second region measurementsmade within the three zones depicted in FIG. 44 . The x-axis is theregions, with the numbers corresponding to the numbered regions on FIG.43 . First region measurements are labeled as Fn (e.g., F1) and secondregions measurements are labeled as Sn (e.g., S1). Thus, regions 1-5 arefirst regions F1, each being in zone 110. Regions 6-10 are secondregions S1, also being in zone 110. Likewise, first regions F2 areregions 16-20 in zone 120, and regions 11-15 and 21-25 are secondregions S2 in zone 120. Finally, regions 31-35 are first regions F3 inzone 130 and regions 26-30 are second regions S2 in zone 130. Thenumbered regions are consistently depicted across all three graphs ofFIG. 44 , but for simplicity, the zones 110, 120, and 130 are depictedonly on the Thickness Map.

The graphs shown in FIG. 44 represent graphically the magnitude ofdifference in intensive properties between first regions and secondregions within any one of the zones, and can be used to see graphicallythe difference in intensive properties for pairs of regions making up amicrozone. For example, one can see that in zone 110 that basis weightbetween the two regions can be substantially the same, but the thickness(caliper) can vary from about 400 microns in the first regions to about40 microns in the second regions, or about a 10× differential. Thevolumetric density in zone 110 can vary from about 0.1 g/cc to about 0.6g/cc. Similar quantifiable distinctions can be understood for each ofthe zones shown.

Thus, with reference to FIG. 43 and FIG. 44 together, furthercharacterization of the beneficial structure of a fabric 10 of thepresent disclosure can be understood. The nonwoven fabric 10 can bedescribed as having at least two visually distinct zones, e.g., zones110 and 120, with each of the zones having a pattern ofthree-dimensional features, each of the three-dimensional featuresdefining a microzone comprising first and second regions, e.g., regions300, 310, and wherein the difference in values for at least one of themicrozones in the first zone is quantifiably different from thedifference in values for at least one of the microzones in the secondzone. For example, in FIG. 43 , two representative microzones 400 inzone 130 are designated as the pair of regions marked as areas 31 and 27and 33 and 26. That is, first region 31 and second region 27 form amicrozone, and first region 33 and second region 26 form a microzone.Likewise, two representative microzones 400 in zone 120 are designatedas the pair of regions marked as areas 19 and 24 and 17 and 22. FromFIG. 44 . Tables 4-7 can be populated as shown:

TABLE 4 Illustrative examples of differences in thickness in microzonesDifference in Thickness Thickness (microns) (microns) Zone Microzone 1First Region 31 1802 1709 130 Second Region 27 93 Microzone 2 FirstRegion 33 2548 2484 Second Region 26 64 Zone Microzone 1 First Region 19242 172 120 Second Region 24 70 Microzone 2 First Region 17 235 183Second Region 23 52

TABLE 5 Illustrative examples of differences in basis weight inmicrozones Difference in Basis weights Basis weights (gsm) (gsm) ZoneMicrozone 1 First Region 31 124 107 130 Second Region 27 17 Microzone 2First Region 33 106 72 Second Region 26 34 Zone Microzone 1 First Region19 32 120 Second Region 24 27 5 Microzone 2 First Region 17 42 SecondRegion 23 12 30

TABLE 6 Illustrative examples of differences in volumetric density inmicrozones Difference in Volumetric Volumetric Density Density (g/cc)(g/cc) Zone Microzone 1 First Region 31 0.069 0.116 130 Second Region 270.185 Microzone 2 First Region 33 0.041 0.49 Second Region 26 0.531 ZoneMicrozone 1 First Region 19 0.133 0.251 120 Second Region 24 0.384Microzone 2 First Region 17 0.185 0.044 Second Region 23 0.229

TABLE 7 Illustrative examples of differences in intensive propertieswithin different zones: Basis Basis Volumetric Volumetric ThicknessThickness Weights Weights Density Density (Microns) Differences (gsm)Differences (g/cc) Differences Zone 130 2147 2118 149 135 0.069 0.423First Region 32 Zone 110 29 14 0.492 Second Region 8

The four representative microzones from two zones are shown in Tables4-6 for illustration. But as can be understood, each pair of first andsecond regions in FIG. 43 could likewise be quantified to furtherpopulate additional rows in Table 4, but for purposes of conciseness arenot. In general, for any fabric having two or more zones, each zonehaving a pattern of three-dimensional features defining microzones, theintensive properties can be measured and tabulated as illustrated hereinwith reference to FIGS. 43 and 44 to understand both the difference invalues for intensive properties within a zone, and differences in valuesof intensive properties between one region in first zone to anotherregion in a second zone.

A microzone spanning two zones, such as zones 110 and zone 130, can havean even greater difference in intensive properties relative to amicrozone within a single zone. For example, viewing the data for amicrozone spanning a first region of zone 130, for example at firstregion 32, and a second region of zone 110, for example at second region8, the microzone exhibits dramatic differences in all of thickness,basis weight and volumetric density. The thickness of first region 32 ofzone 130 is about 2100 microns, while the thickness of second region 8of zone 110 is about 29 microns, or about a 72× differential. Likewise,the basis weight of first region 32 of zone 130 can be as high as 150gsm, while the basis weight of second region 8 of zone 110 can be about14 gsm, or about a 10× differential. Further, the volumetric density offirst region 32 of zone 130 can be about 0.069 g/cc, while thevolumetric density of second region 8 of zone 110 can be 0.492 g/cc, orabout a 7× differential.

For each of the measured intensive property parameters of the variousregions of a microzone, such a measurement is done using the micro CTmethod described herein. The resolution of the method supportsestablishing the intensive properties of microzone regions sodifferences and ratios comparisons of regions as described herein can bedimensioned.

Further characterization of a fabric 10 can be made with reference toFIGS. 45-49 , which are SEMs showing in greater detail certain aspectsof the nonwoven fabric 10 and regions therein. FIGS. 45-49 arephotographs of magnified portions of zone 110 of the fabric shown inFIG. 38 . The nonwoven fabric 10 shown in FIG. 38 was made according tothe process described above with reference to FIG. 7 in which the fabricwas processed through a nip formed by compaction rolls 70 and 72, withroll 72 which contacts first side 12 being heated to cause partialbonding of fibers in the second regions 301. FIGS. 45 (facing the belt)and 46 (facing the heated compaction roll) are SEMs of a portion of thesecond surface 14 and first surface 12, respectively, magnified to 20X.FIGS. 47 (facing the belt) and 48 (facing the heated compaction roll)are photographs of a portion of the second surface 14 and first surface12, respectively, magnified to 90X, and show in detail the beneficialstructural characteristic of the partial bonding of fibers formed bycompaction rolls 70 and 72.

As can best be seen in FIGS. 47 and 48 , as well as the cross sectionalview of FIG. 49 , the heated compaction rolls can cause thermal bondingof fibers to different degrees with a beneficial effect on the overallfabric 10. As shown, the fibers in contact with a heated roll, e.g.,roll 70 in contact with first surface 12 of fabric 10, can be meltbonded such that the first surface 12 experiences relatively greaterfiber-to-fiber bonding than does the second surface 14. In anembodiment, the bonded fibers 80 of the first surface can besubstantially completely melt bonded to form, in effect, a film skin ofbonded fibers, while the fibers in the second region 310 on the secondside 14 can experience little to no bonding. This feature permits anonwoven fabric 10 for use in a disposable absorbent article, e.g., as atopsheet, to maintain physical integrity during manufacture and use, aswell as relative softness on one side, which can be the user-facing,skin-contacting side.

Even in the microzones with the greatest thickness differential, this“bond skinning” effect serves the purpose of maintaining web integrity,while not significantly impacting softness, or other beneficialproperties such as fluid handling properties. As can be understood withreference to FIGS. 50-53 , the differential in the extent of thermalbonding of fibers can be such that fibers on the first surface 12 at asecond region 310 can be complete, or substantially complete, while theextent of thermal bonding of fibers on the second surface 14 at a firstregion 300 can be minimal, to no thermal bonding.

FIG. 50 shows again the portion of nonwoven fabric 10 shown in FIG. 38 .FIGS. 51-53 show magnified images of one microzone, indicated in FIG. 50as a first region 300 and second region 310, which visually appears tobe a hole or an aperture. FIGS. 51 and 52 show the microzone as itappears on the second surface 14 magnified to 40× and 200×,respectively. FIG. 53 shows the second region 310 as it appears on thefirst side 12 under 200× magnification. Fibers in the second region 310are completely, or substantially completely bonded, while fibers in thefirst region 300 are completely, or substantially completely unbonded.The benefit of the illustrated structure is that a microzone canfunction as a fluid pervious aperture, while the bonded regions of thesecond region 310 simultaneously functioning to maintain physicalintegrity of the fabric 10.

Microzones, therefore, play a significant role in the overall physicalstructure and functioning of a fabric 10 of the present invention.Producing relatively closely spaced, precisely designedthree-dimensional features, enabled by the forming belt of the presentdisclosure, a fabric 10 can exhibit visually distinct zones, microzones,and three-dimensional features that provide for functional superiorityin the areas of, at least, softness and fluid handling, as well asvisually attractive aesthetic designs. The potential difference inphysical properties of the first and second surfaces permits thenonwoven fabric 10 to be designed for both strength and softness, bothform and function.

FIG. 54 is a Micro-CT scan image of the portion of nonwoven fabric 10similar to that shown in FIGS. 40 and 41 , but having been subjected tothe additional processing step of forming point bonds 90 in the nip ofcalendar rollers 71 and 73. As above, with respect to the discussion ofFIGS. 43 and 44 , for specific point bond microzones 400 first andsecond regions shown as numbered portions of the nonwoven fabric 10 canbe analyzed, and include regions of point bonds, specifically in thenumbered areas 31-35. For example, adjacent regions 32 and 26 form amicrozone 400 in third zone 130. In FIG. 54 , the specific regions werevisually discerned to identify regions including the added point bondregions and analyzed to measure thickness, basis weight, and volumetricdensity, and the data is produced in FIG. 55 , where the thickness,basis weight and volumetric density of all the regions, including thepoint bond regions are quantified and compared.

FIG. 55 shows data for groupings of first and second region measurementsmade within the three zones depicted in FIG. 54 . The x-axis is theregions, with the numbers corresponding to the numbered regions on FIG.43 . First region measurements are labeled as Fn (e.g., F1) and secondregions measurements are labeled as Sn (e.g., S1). Thus, regions 1-5 arefirst regions F1, each being in zone 110. Regions 6-10 are secondregions S1, also being in zone 110. Likewise, first regions F2 areregions 16-20 in zone 120, and regions 11-15 and 21-25 are secondregions S2 in zone 120. Finally, regions 31-35 are second regions butare point bonds 90 denoted on FIG. 55 as B1 to distinguish them in thisdisclosure as having been formed by a point bonding process. Firstregions F3 in zone 130 are regions 26-30 and 36-40, while regions 41-44are second regions S2 in zone 130. The numbered regions are consistentlydepicted across all three graphs of FIG. 55 , but for simplicity, thezones 110, 120, and 130 are depicted only on the Thickness Map.

The graphs shown in FIG. 54 represent graphically the magnitude ofdifference in intensive properties between first regions and secondregions within any one of the zones of a fabric subjected to acalendaring point bonding step, and can be used to see graphically thedifference in intensive properties for pairs of regions making up amicrozone. For example, one can see that in zone 110 that basis weightbetween the two regions can vary within a range narrower than doesthickness or volumetric density. For example, the thickness (caliper)can vary from about 325 microns in the first regions to about 29 micronsin the second regions of zone 110, or about a 10× differential. Thevolumetric density in zone 110 can vary from about 0.08 g/cc to about0.39 g/cc. Similar quantifiable distinctions can be understood for eachof the zones shown.

In general, regions of a microzone can have broadly varying values forbasis weight, thickness, and volumetric density.

Thus, with reference to FIG. 54 and FIG. 55 together, furthercharacterization of the beneficial structure of a fabric 10 of thepresent disclosure can be understood specifically with respect to thethermal calendar point bonds 90. Focusing for purposes of description onzone 130, three-dimensional features defining a microzone comprisingfirst and second regions which are point bonded regions can beidentified and the values of intensive properties quantified. Forexample, in FIG. 54 , a representative point bond microzone 400 in zone130 can be the pair of regions marked as areas 26 and 32 or 30 and 35.That is, first region 26 and second region 32 form a point bondmicrozone 400, and first region 30 and second region 35 form a pointbond microzone 400.

The differences in certain intensive properties for point bondmicrozones can be seen in FIG. 55 . For example, taking the two pointbond microzones 400 described above, e.g., the two point bond microzones400 of regions 26 and 32 and 30 and 35, respectively, one can see thereis a slight difference in basis weight between the first regions andsecond regions ranging from about 55 to about 60 gsm, but the sameregions exhibit a significant difference in thickness of from about 430microns to about 460 microns to about 125 microns, and a significantdifference in volumetric density of from about 0.13-0.14 g/cc to about0.41-0.48 g/cc. Other differences in intensive properties can beobserved by reference to FIG. 55 .

Bond points 90 may play a significant role in the overall physicalstructure and functioning of a fabric 10 of the present invention. Byadding bond points 90 to the fabric 10 comprising relatively closelyspaced, precisely designed three-dimensional features, enabled by theforming belt of the present disclosure, a fabric 10 can be furtherimproved to exhibit an unexpected combination of visually distinctzones, microzones, and three-dimensional features that provide forfunctional superiority in the high performance combination of softness,strength, low fuzz, and fluid handling, as well as visually attractiveaesthetic designs. The bond point feature provides for a nonwoven fabric10 to be designed for the highest combined performance of strength,softness, fluid handling, and visual aesthetics, especially consideringboth form and function.

One benefit of the shaped nonwoven webs of the present disclosure isimproved softness. Softness can be measured using the Emtec TissueSoftness Analyzer, available from Emtec Paper Testing Technology, EmtecElectronic, GmbH. Table 5 below shows softness values as TS7measurements from the Emtec Tissue Softness Analyzer, according to theEmtec Test Method below. For all of the Examples 7-9 below, the nonwovenwas made on a belt as described in FIG. 16 , with the nonwoven webhaving an appearance similar to that shown in FIG. 2 .

TABLE 5 TS7 Values for Shaped Nonwovens of the Disclosure TS7 ValueExample No. Side (dB V2 rms) Ratio FS/SS Example 7 First Surface 10.301.35 Second Surface 7.59 Example 8 First Surface 3.51 0.98 SecondSurface 3.59 Example 9 First Surface 9.61 1.48 Second Surface 6.47

Example 7

A bicomponent spunbond nonwoven fabric web was produced by spinning a50:50 ratio of polyethylene sheath (Aspun-6850-A obtained from Dowchemical company) and polypropylene core (PH-835 obtained fromLyondellBasell) in a trilobal fiber configuration, as discussed abovewith reference to Example 2. The nonwoven fabric was spun on a formingbelt having a repeating pattern as described in FIG. 16 moving at alinear speed of about 25 meters per minute to form a fabric 10 having anaverage basis weight of 25 grams per square meter with a repeatingpattern of diamond shapes as shown in FIG. 2 . Fibers of the fabric werecompacted by compaction rolls 70, 72, but rather than be calendared,further bonding was achieved by a through-air bonding unit as describedbelow with respect to FIG. 56 , at a temperature of 145 degrees C.

Example 8

A bicomponent spunbond nonwoven fabric that was produced by spinning a30:70 ratio of polyethylene sheath (Aspun-6850-A obtained from Dowchemical company) and polypropylene core (HG475 FP obtained fromBorealis) in a round fiber configuration, using a dual beam spunbondprocess, as described in FIG. 56 . The nonwoven fabric was spun on aforming belt having a repeating pattern as described in FIG. 16 asdescribed above with respect to FIG. 7 moving at a linear speed of about152 meters per minute to an average basis weight of 35 grams per squaremeter to form a repeating pattern of diamond shapes as shown in FIG. 2 .The difference between shaped nonwoven webs made according to theprocess of FIG. 7 , and the Example 8, is that Example 8 was made on ahybrid of the process described in FIG. 7 , and that described in FIG.56 below. Specifically, the process involved two spin beams as shown inFIG. 56 , but the final heating step was by calendar rolls 71, 73,rather than through-air bonding. Fibers of the fabric were bonded onfirst surface 12 by heated compaction rolls 70A and 72A at 110° C. afterthe first beam 48A and compaction rolls 70B and 72B at 110° C. after thesecond beam 48B, and calendar bonded at about 140 C at calendar rolls 71and 73 before being wound on to a reel at winder 75.

Example 9

A bicomponent spunbond nonwoven fabric that was produced by spinning a30:70 ratio of polyethylene sheath (Aspun-6850-A obtained from Dowchemical company) and polypropylene core (HG475 FP obtained fromBorealis) in a round fiber configuration, using a dual beam spunbondprocess, as described in FIG. 56 . The nonwoven fabric was spun on aforming belt having a repeating pattern as described in FIG. 16 movingat a linear speed of about 228 meters per minute to an average basisweight of 25 grams per square meter to form a repeating pattern ofdiamond shapes as shown in FIG. 2 . Fibers of the fabric were furtherbonded on first surface 12 by heated compaction rolls 70A and 72A at110° C. after the first beam 48A and compaction rolls 70B and 72B at110° C. after the second beam 48B, and hot air through bonded at threeheating zones of through-air bonder 76 (as shown on FIG. 56 ) of 100C,135C and 135 C before being wound on to a reel at winder 75.

Examples 7-9 are representative of shaped nonwoven fabrics of thepresent disclosure that exhibit an improved softness, as indicated bythe Emtec measurements. The Emtec measured values can be from about 1 dBV² rms to about 15 dB V² rms, or from about 3 dB V² rms to about 10 dBV² rms, or from about 5 dB V² rms to about 8 dB V² rms. In general, theEmtec measured values for either the first surface or the second surfacecan be any integer value up to about 15 dB V² rms, and any range ofintegers between 1 and 15. Further, in general, the ratio of themeasured Emtec value for the first side to the second side can bebetween 1 and 3 and any real number between 1 and 3.

Without being bound by theory, it is believed that the improvement insoftness exhibited by the shaped nonwoven fabrics of the presentinvention is achieved the method and apparatus of the invention whichpermits for differential intensive properties in relatively small zones,including the disclosed zones and microzones. The ability to design andmake shaped nonwoven fabrics with the disclosed differences in basisweight, density, or thickness, for example, while simultaneouslydelivering a consolidated fabric useful for topsheets in absorbentarticles, for example, breaks a previously held technical contradictionsbetween surface texture and softness. That is, the shaped nonwovenfabrics of the present disclosure may deliver visibly noticeable surfacetexture, including in irregular patterns, as well as superior softness,as indicated by measured Emtec values. Additionally, the shaped nonwovenfabrics of the present disclosure may deliver visibly noticeable surfacetexture in combination physical integrity and reduced fuzzingproperties, as well as superior softness, as indicated by measured Emtecvalues

As discussed above, in an example, a process for making a shapednonwoven fabric can be a modified version of the process described withrespect to FIG. 7 . One modification is described with respect to FIG.56 . As shown in FIG. 56 , the process can include a belt 60 asdescribed above in a melt-spinning process in which more than one spinbeam is employed. As illustrated schematically showing only spin packs48A and 48B, two beams can be used to melt spin fibers onto belt 60,with a compaction operation 70A, 72A and 70B, 72B occurring after eachbeam respectively. Vacuum boxes 64A and 64B can also be operativelyassociated with each spin beam 48A and 48B, respectively.

After spinning fibers onto belt 60, and after being compacted, includingoptionally thermally bonding during compaction as described above, theshaped nonwoven web can be subject to additional heating by through-airheater 76, which can have multiple chambers, such as three chambers 76A.76B and 76C, each independently temperature controlled.

Examples 7 and 9 above were fabricated on a twin beam process line andthrough-air bonded in a process schematically shown in FIG. 56 . Withoutbeing bound by theory, it appears that through-air bonding preservesmuch of the three-dimensionality of the three-dimensional features ofthe shaped nonwoven fabric, as indicated by the difference in TS7 valuesin Table 5. Alternatively, if a less sided shaped nonwoven fabric isdesired, it appears that calendar bonding tends to even out the TS7values, as shown by Example 8 in Table 5. Thus, the process parameterscan be controlled as described herein to achieve predetermined softnessper side, i.e., surface, of a shaped nonwoven fabric.

The dimensions and/or values disclosed herein are not to be understoodas being strictly limited to the exact numerical dimension and/or valuesrecited. Instead, unless otherwise specified, each such dimension and/orvalue is intended to mean both the recited dimension and/or value and afunctionally equivalent range surrounding that dimension and/or value.For example, a dimension disclosed as “40 mm” is intended to mean “about40 mm”.

Every document cited herein, including any cross referenced or relatedpatent or application is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

Test Methods: Compression Aging Test Initial Caliper Measurement:

-   -   Cut five 3 inch by 3 inch samples per nonwoven fabric to be        measured.    -   Number each sample from 1 to 5.    -   Measure caliper at 0.5 kPa with Standard 65 mm foot using        Thwing-Albert caliper tester according to standard procedures.    -   Report initial caliper for each of the five samples.    -   Report the average caliper of the five samples.

Aged Compression Method and Aged Caliper Measurement

-   -   Stack the five samples in an alternating mode with each        separated by a paper towel, the stack starting and ending with a        Sample Number 1 and 5, respectively.    -   Place the alternating stacked samples in an aluminum sample        holder with an appropriate weight on top of the samples (4 KPa,        14 KPa or 35 KPa).    -   Place the stacked samples with the weight in oven at 40° C. for        15 hours.    -   Remove the weight after 15 hours, separate the samples and        measure the caliper of each sample at 0.5 kPa with Standard 65        mm foot Thwing-Albert caliper tester according to standard        procedures.    -   Report aged caliper value for each of the five samples.    -   Report the average aged caliper of the five samples.

Analysis Reports:

-   -   Report average initial and aged calipers by position number    -   Report Caliper Recovery Index:

(Average Aged Caliper/Average Initial Caliper)*100

Localized Basis Weight

Localized basis weight of the nonwoven fabric may be determined byseveral available techniques, but a simple representative techniqueinvolves a punch die having an area of 3.0 cm² which is used to cut asample piece of the web from the selected region from the overall areaof a nonwoven fabric. The sample piece is then weighed and divided byits area to yield the localized basis weight of the nonwoven fabric inunits of grams per meter squared. Results are reported as a mean of 2samples per selected region.

Fuzz Level Test

The Fuzz Level Test is used to determine the quantity of fibers removedfrom a nonwoven materials under an abrasive force (i.e., the fuzzlevel).

The Fuzz Level Test utilizes the following materials:

-   -   Sutherland Ink Rub Tester with 2 lb. weight, available from        Danilee Co. San Antonio, Tex.    -   Aluminum oxide cloth 320 grit shop rolls made by Plymouth        Coatings, (617) 447-7731. This material can also be ordered        through McMaster Carr, part number 468.7A51. (330) 995-5500.    -   Two sided tape, 3M #409, available from Netherland Rubber        Company. (513) 733-1085.    -   Fiber Removal Tape, 3M #3187, available from Netherland Rubber        Company. (513) 733-1085.    -   Analytical Balance (+/−0.0001 g)    -   Paper cutter    -   2200 g weight (metal) 170 mm×63 mm.    -   Thick-style release paper liner cardboard—0.0445 in (1.13 mm)        caliper.

Materials Preparation

Measure and cut aluminum oxide cloth to 7.5 in (19.0 cm) in length.Measure and cut pieces of 3M #3187 tape 6.5 inches (16.5 cm) in length,two tapes for each specimen. Fold under approximately 0.25 inch (0.6 cm)on each end of the 3M #3187 tape to facilitate handling. Lay 3M #3187tape on the thick-style release paper for use later.

Sample Preparation

Before handling or testing any of the materials, wash hands with soapand water to remove excess oils from hands. Optionally, latex gloves maybe worn. Cut a sample of the nonwoven fabric to be tested to a size atleast 11 cm in the MD and 4 cm in the CD. Lay out the sample of nonwovenfabric to be tested with the side to be tested facing down. Cut a pieceof 3M #409 two-sided tape off roll at least 11 cm long. Remove thebacking and apply the side of two-sided tape that was facing the backingto the sample nonwoven fabric lengthwise in the machine direction (MD).Replace the backing over the exposed tape. Using the paper cutter, cuttest samples within the taped area 11 cm MD and 4 cm CD.

Test Procedure

-   -   1. Mount the cut piece of aluminum oxide cloth on Sutherland Ink        Rub Tester using the 2 lb. weight. Lay a second cut piece of        aluminum oxide cloth on top of the thick-style release paper        liner cardboard (a new piece is used for each test). Lay both on        top of the 2 lb. weight. The sides will fold down into        clips—make sure aluminum oxide cloth and the thick-style release        paper liner cardboard are flat.    -   2. Mount the specimen onto Sutherland Ink Rub Tester platform,        centering on the metal plate. Place the 2200 g weight on top of        specimen for 20 seconds.    -   3. Attach the metal plate and 2 lb. weight to Sutherland Ink Rub        Tester.    -   4. Turn Rub Tester on. If the counter light is not illuminated        press the reset button. Press the counter button to set the rub        cycles to 20 cycles. Select Speed 1, the slow speed. (light is        not illuminated) by using the Speed button. Press “Start”.    -   5. When Rub Tester has shut off, carefully remove the aluminum        oxide cloth/weight, being sure not to lose any of the loose        microfibers (fuzz). In some cases, the microfibers will be        attached to both the aluminum oxide cloth and the surface of        Sample nonwoven. Lay the weight upside down on the bench.    -   6. Weigh the fiber removal tapes with release paper attached.        Holding the fiber removal tape by its folded ends, remove        release paper and set aside. Gently put the tape onto the        aluminum oxide cloth to remove all of the fuzz. Remove the fiber        removal tape and put back on release paper. Weigh and record the        weight of the fiber removal tapes.    -   7. Hold another piece of the pre-weighed fiber removal tape by        its folded ends. Gently put the fiber removal tape onto the        surface of the rubbed nonwoven sample. Lay a flat metal plate on        top of the fiber removal tape.    -   8. Lay the 2200 g weight on top of the metal plate for 20        seconds. Remove the fiber removal tape. Hold the pre-weighed        fiber removal tape by its folded ends to avoid fingerprints. Put        pre-weighed fiber removal tape back on release paper. Weigh and        record the weight of the fiber removal tapes.    -   9. The fuzz weight is the sum of weight-increase of both fiber        removal tapes.    -   10. The fuzz weight is reported as the average of 10        measurements.

Calculations

For a given sample, add the weight in grams of fuzz collected from thealuminum oxide cloth and the weight in grams of fuzz collected from theabraded Sample nonwoven. Multiply the combined weight in grams by 1000to convert to milligrams (mg). To convert this measurement from absoluteweight loss to weight loss per unit area, divide the total weight offuzz by the area of the abraded area.

Air Permeability Test

The Air Permeability Test is used to determine the level of air flow incubic feet per minute (cfm) through a forming belt. The Air PermeabilityTest is performed on a Textest Instruments model FX3360 Portair AirPermeability Tester, available from Textest AG, Sonnenbergstrasse 72, CH8603 Schwerzenbach, Switzerland. The unit utilizes a 20.7 mm orificeplate for air permeability ranges between 300-1000 cfm. If airpermeability is lower than 300 cfm the orifice plate needs to bereduced; if higher than 1000 cfm the orifice plate needs to beincreased. Air permeability can be measured in localized zones of aforming belt to determine differences in air permeability across aforming belt.

Test Procedure

-   -   1. Power on the FX3360 instrument.    -   2. Select a pre-determined style having the following setup:        -   a. Material: Standard        -   b. Measurement Property: Air Permeability (AP)        -   c. Test Pressure: 125 Pa (pascals)        -   d. T-factor: 1.00        -   e. Test point pitch: 0.8 inch.    -   3. Position the 20.7 mm orifice plate on the top side of the        forming belt (the side with the three-dimensional protrusions)        at the position of interest.    -   4. Selecting “Spot Measurement” on the touch screen of the        testing unit.    -   5. Reset the sensor prior to measurement, if necessary.    -   6. Once reset, select the “Start” button to begin measurement.    -   7. Wait until the measurement stabilizes and record the cfm        reading on the screen.    -   8. Select the “Start” button again to stop measurement.

In-Bag Stack Height Test

The in-bag stack height of a package of absorbent articles is determinedas follows:

Equipment

A thickness tester with a flat, rigid horizontal sliding plate is used.The thickness tester is configured so that the horizontal sliding platemoves freely in a vertical direction with the horizontal sliding platealways maintained in a horizontal orientation directly above a flat,rigid horizontal base plate. The thickness tester includes a suitabledevice for measuring the gap between the horizontal sliding plate andthe horizontal base plate to within ±0.5 mm. The horizontal slidingplate and the horizontal base plate are larger than the surface of theabsorbent article package that contacts each plate, i.e. each plateextends past the contact surface of the absorbent article package in alldirections. The horizontal sliding plate exerts a downward force of850±1 gram-force (8.34 N) on the absorbent article package, which may beachieved by placing a suitable weight on the center of thenon-package-contacting top surface of the horizontal sliding plate sothat the total mass of the sliding plate plus added weight is 850±1grams.

Test Procedure

Absorbent article packages are equilibrated at 23±2° C. and 50±5%relative humidity prior to measurement.

The horizontal sliding plate is raised and an absorbent article packageis placed centrally under the horizontal sliding plate in such a waythat the absorbent articles within the package are in a horizontalorientation (see FIG. XX). Any handle or other packaging feature on thesurfaces of the package that would contact either of the plates isfolded flat against the surface of the package so as to minimize theirimpact on the measurement. The horizontal sliding plate is loweredslowly until it contacts the top surface of the package and thenreleased. The gap between the horizontal plates is measured to within±0.5 mm ten seconds after releasing the horizontal sliding plate. Fiveidentical packages (same size packages and same absorbent articlescounts) are measured and the arithmetic mean is reported as the packagewidth. The “In-Bag Stack Height”=(package width/absorbent article countper stack)×10 is calculated and reported to within ±0.5 mm.

Micro-CT Intensive Property Measurement Method

The micro-CT intensive property measurement method measures the basisweight, thickness and volumetric density values within visuallydiscernable regions of a substrate sample. It is based on analysis of a3D x-ray sample image obtained on a micro-CT instrument (a suitableinstrument is the Scanco μCT 50 available from Scanco Medical AG.Switzerland, or equivalent). The micro-CT instrument is a cone beammicrotomograph with a shielded cabinet. A maintenance free x-ray tube isused as the source with an adjustable diameter focal spot. The x-raybeam passes through the sample, where some of the x-rays are attenuatedby the sample. The extent of attenuation correlates to the mass ofmaterial the x-rays have to pass through. The transmitted x-rayscontinue on to the digital detector array and generate a 2D projectionimage of the sample. A 3D image of the sample is generated by collectingseveral individual projection images of the sample as it is rotated,which are then reconstructed into a single 3D image. The instrument isinterfaced with a computer running software to control the imageacquisition and save the raw data. The 3D image is then analyzed usingimage analysis software (a suitable image analysis software is MATLABavailable from The Mathworks. Inc., Natick, Mass., or equivalent) tomeasure the basis weight, thickness and volumetric density intensiveproperties of regions within the sample.

Sample Preparation:

To obtain a sample for measurement, lay a single layer of the drysubstrate material out flat and die cut a circular piece with a diameterof 30 mm.

If the substrate material is a layer of an absorbent article, forexample a topsheet, backsheet nonwoven, acquisition layer, distributionlayer, or other component layer; tape the absorbent article to a rigidflat surface in a planar configuration. Carefully separate theindividual substrate layer from the absorbent article. A scalpel and/orcryogenic spray (such as Cyto-Freeze, Control Company, Houston Tex.) canbe used to remove a substrate layer from additional underlying layers,if necessary, to avoid any longitudinal and lateral extension of thematerial. Once the substrate layer has been removed from the articleproceed with die cutting the sample as described above.

If the substrate material is in the form of a wet wipe, open a newpackage of wet wipes and remove the entire stack from the package.Remove a single wipe from the middle of the stack, lay it out flat andallow it to dry completely prior to die cutting the sample for analysis.

A sample may be cut from any location containing the visuallydiscernible zone to be analyzed. Within a zone, regions to be analyzedare ones associated with a three-dimensional feature defining amicrozone. The microzone comprises a least two visually discernibleregions. A zone, three-dimensional feature, or microzone may be visuallydiscernable due to changes in texture, elevation, or thickness. Regionswithin different samples taken from the same substrate material can beanalyzed and compared to each other. Care should be taken to avoidfolds, wrinkles or tears when selecting a location for sampling.

Image Acquisition:

Set up and calibrate the micro-CT instrument according to themanufacturer's specifications. Place the sample into the appropriateholder, between two rings of low density material, which have an innerdiameter of 25 mm. This will allow the central portion of the sample tolay horizontal and be scanned without having any other materialsdirectly adjacent to its upper and lower surfaces. Measurements shouldbe taken in this region. The 3D image field of view is approximately 35mm on each side in the xy-plane with a resolution of approximately 5000by 5000 pixels, and with a sufficient number of 7 micron thick slicescollected to fully include the z-direction of the sample. Thereconstructed 3D image resolution contains isotropic voxels of 7microns. Images are acquired with the source at 45 kVp and 133 μA withno additional low energy filter. These current and voltage settings maybe optimized to produce the maximum contrast in the projection data withsufficient x-ray penetration through the sample, but once optimized heldconstant for all substantially similar samples. A total of 1500projections images are obtained with an integration time of 1000 ms and3 averages. The projection images are reconstructed into the 3D image,and saved in 16-bit RAW format to preserve the full detector outputsignal for analysis.

Image Processing:

Load the 3D image into the image analysis software. Threshold the 3Dimage at a value which separates, and removes, the background signal dueto air, but maintains the signal from the sample fibers within thesubstrate.

Three 2D intensive property images are generated from the threshold 3Dimage. The first is the Basis Weight Image. To generate this image, thevalue for each voxel in an xy-plane slice is summed with all of itscorresponding voxel values in the other z-direction slices containingsignal from the sample. This creates a 2D image where each pixel now hasa value equal to the cumulative signal through the entire sample.

In order to convert the raw data values in the Basis Weight Image intoreal values a basis weight calibration curve is generated. Obtain asubstrate that is of substantially similar composition as the samplebeing analyzed and has a uniform basis weight. Follow the proceduresdescribed above to obtain at least ten replicate samples of thecalibration curve substrate. Accurately measure the basis weight, bytaking the mass to the nearest 0.0001 g and dividing by the sample areaand converting to grams per square meter (gsm), of each of the singlelayer calibration samples and calculate the average to the nearest 0.01gsm. Following the procedures described above, acquire a micro-CT imageof a single layer of the calibration sample substrate. Following theprocedure described above process the micro-CT image, and generate aBasis Weight Image containing raw data values. The real basis weightvalue for this sample is the average basis weight value measured on thecalibration samples. Next, stack two layers of the calibration substratesamples on top of each other, and acquire a micro-CT image of the twolayers of calibration substrate. Generate a basis weight raw data imageof both layers together, whose real basis weight value is equal to twicethe average basis weight value measured on the calibration samples.Repeat this procedure of stacking single layers of the calibrationsubstrate, acquiring a micro-CT image of all of the layers, generating araw data basis weight image of all of the layers, the real basis weightvalue of which is equal to the number of layers times the average basisweight value measured on the calibration samples. A total of at leastfour different basis weight calibration images are obtained. The basisweight values of the calibration samples must include values above andbelow the basis weight values of the original sample being analyzed toensure an accurate calibration. The calibration curve is generated byperforming a linear regression on the raw data versus the real basisweight values for the four calibration samples. This linear regressionmust have an R2 value of at least 0.95, if not repeat the entirecalibration procedure. This calibration curve is now used to convert theraw data values into real basis weights.

The second intensive property 2D image is the Thickness Image. Togenerate this image the upper and lower surfaces of the sample areidentified, and the distance between these surfaces is calculated givingthe sample thickness. The upper surface of the sample is identified bystarting at the uppermost z-direction slice and evaluating each slicegoing through the sample to locate the z-direction voxel for all pixelpositions in the xy-plane where sample signal was first detected. Thesame procedure is followed for identifying the lower surface of thesample, except the z-direction voxels located are all the positions inthe xy-plane where sample signal was last detected. Once the upper andlower surfaces have been identified they are smoothed with a 15×15median filter to remove signal from stray fibers. The 2D Thickness Imageis then generated by counting the number of voxels that exist betweenthe upper and lower surfaces for each of the pixel positions in thexy-plane. This raw thickness value is then converted to actual distance,in microns, by multiplying the voxel count by the 7 μm slice thicknessresolution.

The third intensive property 2D image is the Volumetric Density Image.To generate this image divide each xy-plane pixel value in the BasisWeight Image, in units of gsm, by the corresponding pixel in theThickness Image, in units of microns. The units of the VolumetricDensity Image are grams per cubic centimeter (g/cc).

Micro-CT Basis Weight, Thickness and Volumetric Density IntensiveProperties:

Begin by identifying the region to be analyzed. A region to be analyzedis one associated with a three-dimensional feature defining a microzone.The microzone comprises a least two visually discernible regions. Azone, three-dimensional feature, or microzone may be visuallydiscernable due to changes in texture, elevation, or thickness. Next,identify the boundary of the region to be analyzed. The boundary of aregion is identified by visual discernment of differences in intensiveproperties when compared to other regions within the sample. Forexample, a region boundary can be identified based by visuallydiscerning a thickness difference when compared to another region in thesample. Any of the intensive properties can be used to discern regionboundaries on either the physical sample itself of any of the micro-CTintensive property images. Once the boundary of the region has beenidentified, draw an oval or circular “region of interest” (ROI) withinthe interior of the region. The ROI should have an area of at least 0.1mm2, and be selected to measure an area with intensive property valuesrepresentative of the identified region. From each of the threeintensive property images calculate the average basis weight, thicknessand volumetric density within the ROI. Record these values as theregion's basis weight to the nearest 0.01 gsm, thickness to the nearest0.1 micron and volumetric density to the nearest 0.0001 g/cc.

Emtec Test Method

TS7 and TS750 values are measured using an EMTEC Tissue SoftnessAnalyzer (“Emtec TSA”) (Emtec Electronic GmbH, Leipzig, Germany)interfaced with a computer running Emtec TSA software (version 3.19 orequivalent). According to Emtec, the TS7 value correlates with the realmaterial softness, while the TS750 value correlates with the feltsmoothness/roughness of the material. The Emtec TSA comprises a rotorwith vertical blades which rotate on the test sample at a defined andcalibrated rotational speed (set by manufacturer) and contact force of100 mN. Contact between the vertical blades and the test piece createsvibrations, which create sound that is recorded by a microphone withinthe instrument. The recorded sound file is then analyzed by the EmtecTSA software. The sample preparation, instrument operation and testingprocedures are performed according the instrument manufacture'sspecifications.

Sample Preparation

Test samples are prepared by cutting square or circular samples from afinished product. Test samples are cut to a length and width (ordiameter if circular) of no less than about 90 mm, and no greater thanabout 120 mm, in any of these dimensions, to ensure the sample can beclamped into the TSA instrument properly. Test samples are selected toavoid perforations, creases or folds within the testing region. Prepare8 substantially similar replicate samples for testing. Equilibrate allsamples at TAPPI standard temperature and relative humidity conditions(23° C.±2 C.° and 50%±2%) for at least 2 hour prior to conducting theTSA testing, which is also conducted under TAPPI conditions.

Testing Procedure

Calibrate the instrument according to the manufacturer's instructionsusing the 1-point calibration method with Emtec reference standards(“ref.2 samples”). If these reference samples are no longer available,use the appropriate reference samples provided by the manufacturer.Calibrate the instrument according to the manufacturer's recommendationand instruction, so that the results will be comparable to thoseobtained when using the 1-point calibration method with Emtec referencestandards (“ref.2 samples”).

Provide eight replicate samples of a fabric for testing. Mount a testsample into the instrument with a surface facing upwards, and performthe test according to the manufacturer's instructions. When complete,the software displays values for TS7 and TS750. Record each of thesevalues to the nearest 0.01 dB V² rms. The test sample is then removedfrom the instrument and discarded. This testing is performedindividually on the same surface of four of the replicate samples, andthen on the other surface of the other four replicate samples. The firsttested surface may be either of the first surface 12 or the secondsurface 14 of a shaped nonwoven fabric as disclosed herein.

The four test result values for TS7 and TS750 from the first testedsurface are averaged (using a simple numerical average); the same isdone for the four test result values for TS7 and TS750 from the secondtested surface. Report the individual average values of TS7 and TS750for both the first and second tested surfaces on a particular testsample to the nearest 0.01 dB V² rms. Additionally, the TS7 ratio of thefirst tested surface to the second tested surface is calculated bydividing the average TS7 of the first tested surface divided by theaverage TS7 of the second tested surface.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A nonwoven fabric comprising: continuous fibersforming the nonwoven fabric, comprising: a first surface, a secondsurface, and a visually discernible zone on the second surface andextending from the first surface, the visually discernible zone having apattern of three-dimensional features, wherein the first surface hasgreater fiber to fiber bonding than the second surface, and wherein aportion of the second surface has little fiber to fiber bonding, each ofthe three-dimensional features defining a microzone comprising a firstregion and a second region, the first and second regions having adifference in values for an intensive property.
 2. The nonwoven fabricof claim 1, wherein the intensive property is thickness, and wherein thethickness of every region is greater than zero.
 3. The nonwoven fabricof claim 1, wherein the intensive property is basis weight, and whereinthe basis weight of every region is greater than zero.
 4. The nonwovenfabric of claim 1, wherein the intensive property is volumetric density,and wherein the volumetric density of every region is greater than zero.5. The nonwoven fabric of claim 1, wherein fibers of the nonwoven fabricare thermally bonded at the second regions on the first surface.
 6. Thenonwoven fabric of claim 1, wherein the nonwoven fabric is hot-airthrough bonded.
 7. The nonwoven fabric of claim 1, wherein fibers of thenonwoven fabric are thermally bonded at the second regions on the firstsurface, and wherein the second regions are fluid permeable.
 8. Thenonwoven fabric of claim 1, wherein the continuous fibers are continuousspunbond fibers.
 9. The nonwoven fabric of claim 1, wherein a firstplurality of the three-dimensional features have different Z-directionmaximum dimensions relative to the first surface, and wherein a secondplurality of the three-dimensional features have substantially the sameZ-direction maximum dimensions relative to the first surface.
 10. Thenonwoven fabric of claim 1, wherein the nonwoven fabric is made on adrum.
 11. The nonwoven fabric of claim 1, wherein the first surface orthe second surface has a TS7 value of less than about 15 dB V² rms. 12.An absorbent article comprising the nonwoven fabric of claim
 1. 13. Theabsorbent article of claim 12, wherein the nonwoven fabric is atopsheet.
 14. The absorbent article of claim 12, wherein the nonwovenfabric is an outer cover.
 15. A nonwoven fabric comprising: continuousfibers forming the nonwoven fabric, comprising: a first surface, asecond surface, and a visually discernible zone on the second surfaceand extending from the first surface, the visually discernible zonehaving a pattern of three-dimensional features, wherein the firstsurface has greater fiber to fiber bonding than the second surface, andwherein a portion of the second surface has little to no fiber to fiberbonding, each of the three-dimensional features defining a microzonecomprising a first region and a second region, the first and secondregions having a difference in values for basis weight, and wherein thebasis weight of every region is greater than zero.
 16. The nonwovenfabric of claim 15, wherein the nonwoven fabric is hot-air throughbonded.
 17. The nonwoven fabric of claim 15, wherein fibers of thenonwoven fabric are thermally bonded at the second regions on the firstsurface, and wherein the second regions are fluid permeable.
 18. Thenonwoven fabric of claim 15, wherein a first plurality of thethree-dimensional features have different Z-direction maximum dimensionsrelative to the first surface, and wherein a second plurality of thethree-dimensional features have substantially the same Z-directionmaximum dimensions relative to the first surface.
 19. The nonwovenfabric of claim 15, wherein the nonwoven fabric is made on a drum,wherein the first surface or the second surface has a TS7 value of lessthan about 15 dB V² rms.
 20. A nonwoven fabric comprising: continuousfibers forming the nonwoven fabric, comprising: a first surface, asecond surface, and a visually discernible zone on the second surfaceand extending from the first surface, the visually discernible zonehaving a pattern of three-dimensional features, wherein the firstsurface has greater fiber to fiber bonding than the second surface, eachof the three-dimensional features defining a microzone comprising afirst region and a second region, the first and second regions having adifference in values for basis weight, wherein the basis weight of everyregion is greater than zero, and wherein the second regions on thesecond surface have little to no fiber to fiber bonding.